Fixed it
The answer, if anyone's interested, was that /etc/Networks/interfaces had the wireless card SSID and key data under ra1 while the OS had the card as ra0. Editing the interfaces file to ra0 and rebooted and it was working straight away. I think I had problems when doing the original instal and ended up with two instances of the card (ra0 and ra1) but the version upgrade, correctly, only found one instance and called it ra0 but there was no SSID/key data for it.
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