To cut a long story short I fixed my problem, I just don't know what caused the problem.
Recently I tried to create an LR catalogue (latest CC), I built up several thousand images in 1:1 previews to a 4tb drive. I used an external drive, then suddenly the 4tb quit on me. I got messages saying LR would need to repair the catalogue which it tried to do, but later said it could not be fixed. I thought it might be an issue with the external drive, so I tried another drive, this again allowed me to build up a sizeable catalogue before it too quit.
At no point was I anywhere near filling the drives. I then tried to build the catalogue in the D drive of my PC and it worked fine. So today I pulled the 4tb drive out of it's external housing and put it into the PC. It's now working fine and has built up several thousand images into the LR catalogue. So there was some issue, LR didn't want to be creating a catalogue to an external drive, but it appears to work if the same drive is now an internal drive. I guess this is difficult to understand, I just wondered if anyone has had this before as it doesn't fill me with a lot of confidence.
Many thanks in advance