There was actually a burr on it a few weeks ago. Took flippin ages to sand it down and polish it.
However, I have (I think) solved the problem. More or less. Your suggestion to make sure the case was seated correctly had me thinking. It was seated flat, but there was a fair bit of play. I might have bent the spring mentioned the first time I tinkered around inside there. So, with the correct and specialist tool (a dinky flat headed screwdriver
) I wedged it in and bent the spring back out slightly so the bobbin case doesn't move around so much. A few stitches later and it's running quieter