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Hi Danny. Thanks again for the detail.
I will be getting a new SD card on Monday so will try a fresh install, as all my up to date Rpi's are running fine. Just to check there no significant changes.

Thanks for pointing out the apostrophe issue, my text edit sneaked that one in.
Also the dnsmasq bug. It's not been an issue for me even though using the bugged version but obviously can have an affect. That will also break the other autohotspot script, as yet nobody has reported the issue.

My user path includes sbin /usr/local/sbin:/usr/local/bin:/usr/sbin:/usr/bin:/sbin:/bin:/usr/local/games:/usr/games
and sudo's PATH=/usr/local/sbin:/usr/local/bin:/usr/sbin:/usr/bin:/sbin:/bin
it also works in autohotspot if I enter /sbin/iw ... could also try sudo /sbin/iw ....

I haven’t consciously added it so don't know why it is not in your path. but it should work with /sbin/iw.

if you stop the cron job and run the sudo /usr/bin/autohotspot from a terminal does it work ok when you swith the router on and off?