Hey how did you do this? I need to sort my wallet out as its getting unusable now with the usable transaction size shrinking every time I make a transaction
Just keep lowering the send amount until it goes through. That's really the only way. So try 100k, then 95k, 90k, etc. and continually drop. Once a transaction sends, start at the top again (100k, 95k...) and keep doing that until you've gone through all your coins (cycled). And then you can send ALL the coins in one (hopefully) transaction a final time.
You can also use coin control to go through and select... say 75 inputs at a time. Then at the top of the client you can see the total you can send (after fee), so input your address to send to, the after-fee amount, and that will knock out 75 inputs. Then just keep doing this over and over and watch the input list drop,

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Hi I tried that, it now wont let me send anymore than 10k in one transaction.
So I need two seperate wallets installed then? if not how do I get coins out of wallet_old.dat when the wallet software is reading from Wallet.dat?
When renaming the wallet.dat into oldwallet.dat and you start then a fresh wallet is created.
Copy the new address in a file and rename the new wallet to new wallet.dat and then rename oldwallet into wallet.dat and start software again.
Send all you have in 10k portions to the new address and after finish rename again wallet.dat into oldwallet.dat and new wallet.dat into wallet.dat and restart wallet software.
Now your cons are available and yoyo can send then all in one transaction to whatever address you want.
All the steps are described in my post.
I you want to prevent huge number of new transactions again keep most coins offline and rename wallets if you want to get your stake reward once in a while.
Success and have patience the transactions keep time when you have very much transactions (and blocks) in you wallet.
It took me 4 hours to transfer 21M into a 4 block wallet.