OK quick update:
Completely reinstalled, still had the I/O error pop up.
Did a deep scan on the entropia folder, and found that even after fresh install texture.pak was corrupt.
Fixed the file....
Ran the client and updated 7 of 7, died at the end of 7, same I/O error.
Manually ran todays patch, it failed on a rocktropia file.
Re ran the file manually again and it completed.
Upon restarting client, repair was triggered...found textures.pak filesize was a mismatch.
LOL
SO repair tool is redling the texture.pak file now, just wanted to update my progress so far so others have some info.
Hope to be ingame soon *crosses fingers*
Jack