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[Abiton]

While you've got the barrel out and the tumblers all visible, experiment with the in-out position of the key to see if there's a position slightly less than fully inserted where the tumblers all sit nice and flush with the surface.

On ours, simply inserting the key a couple of mm less than fully seemed to do the trick.  I wonder if the tumblers wear at the contact points with the key; then with key fully inserted, the tumblers fall too far into the notches in the key.  Pull the key out a tad, and the tumblers climb up the slopes adjacent to the bottom of the valleys, and end up nice and flush with the outside.

If this does turn out to be the case, just wrap something around the hilt of the key to stop it going in so far, jobsa gudun.

Don't forget to fettle up the inside of the lock bit as well as the corners of the tumblers that bear on that surface. Failed attempts to turn the key soon generate some burrs on that inside surface.

[hotel21]

On a similar tack and, I think, what Andy b was hinting at....

If the barrel with pins is visible with key inserted, rather than withdrawing the key slightly, you could also file the parts of the lock flush with the housing, thereby 'customising' a (random) key/barrel to 'your' key, absolving you of the need for a differrent key for door locks and ignition....   

[ali]

I managed to get the key to turn, to get the barrel out, but since then I cannot get it to turn to take the barrel apart Ive tried lots of different positions of wiggling but so far it wont move. So if  Welung666 you have a matching door lock and thats easy to change :-? that maybe the answer. Neither of my keys work in the passenger door and due to my location and need of 4 x 4 both estates are going on ebay very soon so it would be good if door and ignition were the same key.

[ali]

A little more wiggling and have now got it apart so theres still hope

[ali]

The barrel from  Welung666 arrived but with a different key to mine so imoboliser wouldnt fit So took both barrels apart, writing down the numbers and started to rebuild worked out I could use tumblers from both barrels to make one working one just used the numbers either side of the orignal order to allow for wear shame Ive run out of daylight, so will have to wait until tomorrow to fit back in the ignition.