I fixed this by resetting to factory defaults and starting fresh. All I can think is that at some stage I must have made a config change that hadn't happened yet, waiting to reboot. Then I rebooted, and the latent change stuffed the m0n0wall. Aah, another several hours wasted, never to be seen again... This time I snapshotted the 'known good' config in VM. I'll back up the config now too.
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