Thanks for the comic relief...
For such a simple object there simply isnt much that can go wrong...
its obviously the internal baffle...
I was looking for confirmation as i cant find any similar experiences on any forum, so needed confirmation that a fully welded object can have somthing knocked loose!!
Even with a screwdriver i cant cause the baffle to move or shake! So its probably poorly spot welded and only one or more spot welds are broke...