Ok leave it with me and I'll try and do more testing, the first issue is becoming less of an issue now so might have just been a glitch and coincidence I had two in a row.

Is there a way you can manually force a customers cart to process in the event of such an occurrence? I.e if you know the customer has paid but the order doesn't create? Would be great to have a list of unapproved orders and the ability to manually approve?

Please stay on this thread and I'll post back when I have more info, cheers Doc