Yes, WordPress MU Domain Mapping Plugin. http://wordpress.org/extend/plugins/wordpress-mu-domain-mapping/
Don’t know but I did notice on the debugging page that there are intermittent issues : http://codex.wordpress.org/Debugging_a_WordPress_Network,
Fixed it. Took me ages!
I think it was a combination of things but made more allowoverride all changes, then completely re-installed everything including a new .htaccess file.
I have a sneaking suspicion it might be something to do with wordpressMU plugin wp-config settings as now all is fine.
I would be interested to know if anyone else has managed to fix this in a more structured way rather than guessing?
Have a great day guys 🙂