YANBU, and I appreciate you are upset,
I don't think it's reasonable for him to take your son abroad, especially as he's made threats and abducted him previously..
If he's on that salary, then it would be incredibly unreasonable for him to expect you to pay his court fees, that's for sure.
As you have full residency and he has visiting rights, I'd guess that the balance of power would be on your side of things, in any court.
the way he's bullying you and abusing you is not on... this is the first thing you need to deal with and I would take fairly drastic steps (like report it to the police, especially if there are threats involved).
BUT....
"He has refused to help with any additional costs with his son eg swim lessons,school clothes etc says thats what he pays his £198 a month maintenance for! "
He's right.
"he wants me to travel more to meet him half way for collection" he's being fair here - if it was you that moved away, then you should expect fairly to take some of the cost and inconvenience.
"and wants to take him abroad" - this is unreasonable and the court has already ordered him not to without your permission. It's unreasonable as he's already abducted and threatened in the past.
"and also wants me to pay for his court fees" if he's earning £40k this is also unreasonable.
I'm just trying to see the other side of this. Did he feel that he wasn't getting fair access and was that why he didn't return your son? Or was he fighting you for residency all along?
Did he feel (as I would) that you moving 100 miles away was unreasonable? (assuming you did from your original post)
You said you 'gave him' the access he requested - I wonder if you stared from a 50/50 standpoint and went from there?