All fixed, thanks, there was some good tips here.
I had configured the alix radio to have a clone interface and I left that disabled. problem was that the firewall still blocked that interface. You must either fully config with IP, DHCP, firewall rules etc or completely remove the clone. The randomness must have been the clone grabbing the packets with sometimes the main WIFI getting them
also had to add a firewall rule to allow UDP 68/67 from 0000 to 255.255.255.255, strange as I didn't need to do that on the LAN.
I don't think this is the original posters problem, problem sounded the same but in the end mine was specific to wifi, not the second interface