I am not going back to read this whole thing, but what kind of ground glass do you have? If you have a fresnel between the lens and the actual focusing surface that could account for the focus shift. I'd check that. The preferred arrangement would be lens/ground glass/fresnel. The fresnel could be incorporated in the screen as well, so make sure the screen isn't in upside down.
It is just a very simple piece of glass, matted on one side. No Fresnel lens.
