Turns out on closer inspection, the gear cable was at fault here, it had split and frayed in the shifter. Believe it or not, this is the second gear cable in 10000 miles to have frayed inside the (105) shifter. Luckily I had a section just long enough, within an inch, so all fixed.
but I have recently experimented with my new high value torque wrench (cannae be bothered to find the thread now) and 40Nm was 6 clicks
but egregious comes from the Latin, is used in modern Italian (egregio) and means illustrious, most esteemed.