I'm afraid I can't do screen dumps as the fault is on a stand alone system.
However, /boot/grub/menu.lst looks fine.
The original kernel boots of sda6 fine as expected. The menu.lst shows '0,5' as the hard drive and partition location.
The new kernal has exactly the same '0,5' as a boot location and has a valid vmlinuz and initrd file location.
When I made the kernel, I based it on the working kernel .config file so all should be well.
However, the new kernel doesn't seem to be able to see the hard drive partition sda6 on boot up.
I'll see if I can get any more menu.lst info to you soon.
Thanks again for your help,