We've (sort of) figured out the material scale problem.

Lee Randall also had his display units set to imperial but the scale was right on loaded materials.

I did some changing around - my internal unit was set to Yards, that's when it was making the scale 1.09. 
If I set it to Feet then the scale comes in at 3.28
Set to Inches then it's 39.37

Having the internal unit set to Imperial screws it up and it seems Vue then converts thing sto metric (on the assumption of there being 39.37 inches to 1 metre). 
I set it to Metrres but left the Display Unit at Imperial and now it does'nt change the material scale.

I still can't say if this is happening in just the lates build or if it happened in earlier builds - I only just noticed it......

Gill