So i got my new seals and decided to measure everything up again, starting with the valve guide projection from the head, i.e. how far they were pressed into the head... and this looks to be the issue.
Almost all of them arn't quite pressed into the head far enough, with the worst (in cylinders 2 &3) being 0.25mm too far out. So I guess the valve keepers may have been tapping on the valve seals, which is what wore them out.
I'm thinking of replacing the exhaust valves now too as according to my measurements they are about 1/2 worn, and if this all works I shouldn't have to rebuild it for a long time.
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