Update on the above, repair kit arrived and fitted, tolerance seemed tight with the gap between the overlap of the large cogs but a little careful alignment and a smidge of lithium grease on the flat overlapping surfaces of the two cogs and all seems good, flap is nicely operational again.
One shortish test drive up to temperature and I cannot recall the little A2 ever being this smooth? Light engine load through to 'pressing on' it is just utterly brilliant. Probably more 'poke' too and I suspect fuel efficiency will leap up. I was running mid 50's which ain't bad at all but you can see the numbers staying higher on the real time mpg read out. Perhaps the ASV operation degrades over time but only when the flap sufficiently sticks does it flag an engine fault code and engine management light?
Light still on for now but I assume that it needs to be cleared now the ASV is operational again. If it stays on I will be in touch
@depronman