Thanks John for all your help - you saved this customer's xbox!

OMG!
I had given up - re-packed the xbox in the box ready to give back...
I had tried:
Replacing the DuoX2 chip with a DuoX2 GS
Re-soldering all
Re-installing old HD.
Downloaded Slayer V2.7 (Already had 2.6 installed but found there was a new version).
Scanned multiple forums for several hours.
Pleaded for help.
Tried a number of component tests to check for part failure - no obvious problems
Received the Enigma software - looked complicated to set up and I had convinced myself it couldn't be as simple as PAL being swapped to NTSC due to the tray closing by itself and no sound...
Checked ribbon cables etc
Got the HD / S-Video cable from the customer - tested - got no where. Not even sound
Played with my LCD TV to try various input modes - Gave up last night a 3am
Packed up.
Received a PS2 to work on - thought well whilst I am setting it up ready to mod I should at least try creating the Enigma disk and testing...
Created the disk.
Tested.
Cried - it was now working!!!
Note - never ever change a PAL station to NTSC = very very bad!
All ready to be collected
Glad that one is over - I hate these problems!
Note to installers - get the switcher - it works wonders!! Slayer V2.7 + Switcher = essential tools of the trade!!

Thanks once again Darkmatter!!