I'm going to say Sammich lives!
Turns out to have been a few issues compounding into one wonky Sammich.
Bank sticks issue - I'm fairly sure this was PSU related. I've moved to a 2A 12v switching supply that I used for a Tripath amp previously. I'll look for a better quality linear (or build my own).
CS and LED issues - putting this down to poor solder work. When I built this box 3 years ago, it was about my 3rd ever proper project and I was using lead free process with a 300 degree C tip and cheapo Chinese fake flux. I ended up using a heat gun to pull the resistor network below the first CS register, cleaned up the pads and resoldered. After this work the bottom left switch was acting up causing all kinds of CS weirdness (gently tapping it made the issue occur).
Heat gun removed and resoldered the switch.
Reflowed most of the board with the heat gun and my soldering iron (mine is now a toasted Sammich ;) )
After that - Sammich played nice for the rest of the evening - both in Sidplayer mode and synthesis.
Thanks for all your help and moral support. I can now haz Sammich.