Thanks for all the replies and suggestions. I've got it all sorted now :D It was just as Nutduster stated, the hard safe zone was causing the problem.
Ah, hadn't thought of it that way round. Thank you, i'll try that when I get home later!
Now, i'm not an 'advanced' forger like all you lovely chaps (and chapettes if there are any reading this), however i'm not an absolute beginner...
Joined so I could add my potentially irrelevant 2 cents and because i'm just a big lorewhore ^^ [spoiler]