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It's possible that your rebuild started life as a different tube #. These early square crts went through a few changes in geometry as they went through various manufacturing changes.
I know my 17" Sentinel is a real pain to get back in the cabinet, showing the exact same symptoms you describe. I just really have to mess with it to get the mask to line up right, or else the controls won't stick out far enough.
Right now, though, I would just focus on seeing that your tv is working before fussing over this setback.
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