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Hi Troy,
I had a chat with Jim Fry last year about some of these sorts of issues, one that affected me was focal plane distance.
When you insert an eyepiece or camera, your focal plane is between 2-6cm above the focuser. Whereas when you collimate you probably arent collimating at your focal plane as the catseye tools are quite low profile.
This problem is easily visible as one of the two overlapping images is larger than the other. It just means racking out the focuser to "expected" focal plane distance (this could also mean adding an extension tube).
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