Happy days!!! it was indeed a problem with a corrupt movie file .mov. I couldn't find it by scrubbing through the full timeline for some reason, so, I broke down the full 43 mins to 'chapter' segments that were naturally within the project anyway (not chapter markers), copy & pasted to new projects and exported individually a chapter one by one. It was during the 5th chapter export where immediately it failed. I changed the clips one by one as it was more managable in 4 min chapters, but still no black frame. I scrubbed the original clips in the media section and eventually found the culprit. It was the only 'mov' file amongst 'gopro' and 'img' files. No matter how much cutting/splitting/range picking I did it just kept creating extra black frames. I just got fed up and deleted the entire clip and replaced with a different clip.
Exported fine, and just need to copy and paste this 'chapter' back into the full project.
I hope this adds to troubleshooting ideas guys, it really annoyed me as it was slightly different from other problems I've read, but thanks for the tips so I could start looking!!
oh and in regards to only creating a 7sec audio file?? No idea why this happened, would have been nice if it was like previous posts 'created a file to the point of error', could've found it straight away.
Enjoy!