@WBYeats,
Your apology is welcome, and is accepted.
To continue, now I've had a few days to think about this: it's difficult (and sometimes dangerous) to try to formulate a rule. Exceptions will always crop up.
I think it might be useful, in general, to think of WORKING ON to be about a single project.
example:
He's working on his fitness/ improving his manners/ his PhD/ his image/ his boatbuilding project.
and WORKING AT to be more general.
There is some overlap of course, and there are regional differences too.
As mentioned before, it's not a big mistake to swop (or switch) one for the other.