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sorry to here about that, but if you decide to replace the secondary mirror, then here are some idea's regarding collimation.
I have a telescope much the same as yours, yes they are a pain in the bum to collimate, but it is possible. I don't own any collimating tools, which makes it all the more challenging, but it can be done. I also had the problem of seeing all stars as doubles, but the problem disappeared after I collimated the damn thing. I find that the best way to collimate my 'scope is to get every thing aligned during the day as you would on any other newt, but follow a different procedure at night: I point my telescope at a bright star, and adjust the main mirror. When I move the mirror the right way (after some trial and error), the two images slowly move together to form one. after that, I just follow normal newtonian procedure for all the fine tuning.
I've only ever seen the 'double star' once, after a very long and bumpy car trip. although in your case, bad collimation may not be the cause. I think the best cure for this issue, at least in my opinion, is to get a new telescope (or at least a new OTA, as your happy with your mount), because having to collimate the bugger has spoiled a lot of fine nights.
Jarrod
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