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Ah, you do have a barlow attachment, then.
Use that to adjust the primary mirror, not the return beam-only method. Get the shadow of the primary center mark centered around the hole in the back of the barlow attachment. In "barlow" mode, mis-collimation of the laser won't matter. Then, see if that agrees with the Chesire.
Then compare the agreement using the primary laser to align the secondary and the return-beam method to align the primary.
If the former method agrees, but the latter disagrees (as you say it does now) then I'll bet you it's the laser's collimation as the issue...
S
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