I came up with using a fixed width font, such as courier then in the calc which creates the results, I simply added a number of spaces depending on the data being returned
i.e
Case (not IsEmpty ($disp1) ; Left($disp1 & " " ; 8 )) &
For this particular field, it was only ever going to have a max of 8 characters, so when only 2 where used, 6 spaces would be added to the end.
I then decided to add column headers, altough this required a little 'hard-coding' I think its quite neat...
To do this, I copied how the initial header was being added, then wrapped it in If / Else statements
If [$param = "01"]
Set Field..... my headings using fixed width font
Then increased the line & record count by 1.
[else if $param = "02"] etc etc
The end result can be seen below.

P.S This is still a work in progress