Thanks - but I actually managed to suss it out by looking at all the various answers to similiar posts I was that impressed with myself I wrote a guide!!!
Extending a WiFi / Wired Network using a DLink G604T(Second Router)/DWL-2000AP+(Access Point) and DES-1005D(4 Port Network Switch).
The steps below show how to setup a second router, in this case a DLink G604T, as an AP and connect it to another AP (DWL-2000AP+) configured in Wireless Client Mode allowing you to extend a wired LAN and connect multiple devices to the internet using a using a 4 port switch (DES-1005D).
This should work for other routers and other hardware.
1. Reset second router to factory settings, my Dlink is reset by holding down the reset button for 10 seconds with the power on - I had to resort to a custom reset for my DLink which I found here some time ago - https://www.expansys...ft.aspx?k=53282
as occasionally when Iv'e been playing around with it it crashes and a standard reset will not work.
2. Connect a wifi enabled device to to the second routers admin screen by navigating to http://<ip address of second router> for the G604T it was http://192.168.1.1
in a web browser.
3. Disable DHCP on the second router.
4. Change the management IP to be in the same range as the main router - I changed my G604T to 192.168.1.200.
5. Power up the second AP (The one that will be the wireless client on the other end of the extended WiFi network).
6. Reset to factory defaults - mine was reset by pressing the reset button for 10 seconds.
7. Connect the second AP to a PC using an ethernet cable.
8. Open Network Connections on the PC and assign a static IP Address in the same range as the second AP that you are connected to - mine was set to 192.168.0.51
9. Open an IE browser and connect to second APs admin page by entering http://<ip address of the second AP> - mine was http://192.168.0.50
10. Enter the admin screen usually admin <no password> but check your specific model manual.
11. Now it gets a bit hazy here on my DWL-2000AP I had to select Advanced - and change the mode to Wireless Client and carry out site survey, this is to find the AP that you want to connect to and enter its SSID and mac address to ensure that the AP now in wireless client mode knows which AP to connect to (consult your specific models manual.
12. Once the site survey was completed it found my second router (my G604T) and I clicked connect.
13. Close the connection window.
14. Apply changes to the AP - my device auto re-started
15. Exit browser web browser.
16. Disconnect the second AP from PC.
17. Re-connect the second AP to the 4 port switch.
18. Remove static IP address from PC.
19. Re-connect the PC to the 4 port switch.
19. Check IP address - IP address should be assigned by and be in the range(subnet) of the main router (My assigned IP Address was 192.168.1.65)
20. Test internet connection.
21. Login to second router, by entering the second routers IP Address in a we browser as above - mine was 192.168.1.200 and change wireless encryption to WEP or WPA the highest that your AP (Wireless Client) can handle, and enter an encryption key - write it down for the next step and keep it safe as any WiFi devices that need to access the second router will also need the same key. It may also be a good idea to set an admin password for the second router to avoid unwanted access.
22. Carry out steps 7-10 above and set WEP or WPA as chosen above in step 21, and also set an admin password for the second AP.
23. Reconnect the AP to the 4 port switch and remove the static IP address from the PC that was connected to the AP to set it up.
24. Fingers crossed check internet connection.