Problem 1 and 2 solved. Motor works fine on 240v with the vfd and got the gearbox fixed so all 4 speeds are working.

I wasnt going to bother fixing the gearbox as the vfd would have taken care of the speed control but unfortunately though the 1 speed that worked was the slowest (350rpm ish). The previous owner had some replacement gears made but they didn't quite match the gear profile so I had to file them down, not ideal but needs must and at least I can test the rest of the machine.

A BIG THANK YOU to all that have help sort his especially Geoffery, M-C and Swarfing, cheers guys I know most of the info is somewhere on the net but to have you point me in right direction is great.