Obvious first question is whether the firewalls are open between the two. As mentioned, I set up the servers separately with IP addresses on vSphere, but they are on different networks to the Rancher cluster, so ports 80/443/6443 are opened up for them to communicate, after which the curl command for registration can be run on the new server to give it a role or three in the cluster. The cluster is set up with no reference to any servers at all, hence needing the registration command to run curl.