Many thanks Biffo
I now have 40ac. I was wondering where and when he'd appear.
I know 59's real name and so have a solution that is too short for 46ac. Is it a theme solution or one of the 36? I've not heard of Excalibar in the context of a theme word.
I have yet to solve the anagram despite having lots of crossers. I need to solve 24ac to get the last crosser.
I have been a bit stupid. Of course some of the numbers on the grid have both across and down solutions. Doh!