Chris,
Sorry but it's time to bite the bullet and go VAT registered, you can duck and dodge for a while, you can set up another business, it has to have different directors/owners, but you are getting on thinner and thinner ice!
Take the dive, go VAT registered, ideally go for FLAT RATE VAT, which means you only pay the vat man 10% of your turnover but you can't claim back vat on any of your smaller expenses.