My current thinking is I might try him on his own for a couple of days then introduce the 3 hens I really want to breed him with then gradually add more
I would not bother putting him on his own, just give him those 3 most important hens. I think that has the best chance of getting fertile eggs from those hens in a timely fashion.
I'm not sure about adding more: he might handle them just fine, but the people worrying about flock disruption are also making a valid point. Maybe see how the first 3 go, and then decide.
bit of a timeline on that though as I'll need the second pen for a broody in 3 weeks and I've got people clamouring for fertile eggs too.
If it works, you may consider whether you can divide the main pen, so the rooster can stay with a small number of hens and the other hens can be in the other part of the pen.
And if it does not work, at least you will know you tried that, and then you can figure out what to try next.
I've had some hens that were fertile a month ago are no longer fertile. For example the only fertile eggs in the last 2 hatches were from a leghorn that lays the only white eggs I get but the most recent check showed no fertility in her eggs. I have 3 cream legbar hens and in the last week I've seen him mating with a cream legbar hen every time I go out but never with an araucana.
Some people say they can tell fertility accurately by looking for a bullseye, but I know that some people (including myself) cannot. I have tested it by cracking one egg to look for a bullseye, then incubating an egg from the same hen, laid the day before or the day after, repeated across multiple hens. For me, I am wrong at least as often as I am right, with my "wrong" being both directions (I think it's fertile but it is not, or I think it is infertile but it really was fertile.) I've tested enough times to prove that *I* cannot accurately tell by looking for bullseyes, even though apparently some other people can.
So if you are determing fertility by looking for bullseyes, you might consider incubating some eggs to check whether they are actually fertile and you are just not recognizing it.