Success. I got it working. Apart from the voice, still working on that.
But before going on. I had the old rac 256mb rac sd card, phoned them and said it didn't work anymore (remove a file or two). They said send it in to be fixed, free. Aparently it's a life time support thing. They sent me back a 2gb card with a much better program. Still route 66 but it actually doesn't get lost on my drive! Fair play to the rac, their service is brilliant.
Are you both based in the uK? If you are I can upload my igo copy to rapidshare!
EDIT: Before I do, put igo on your card with the maps, renaming the igo.exe file. BUT take out the sys.txt file completley!