On Sat, 26 Jan 2013 09:42:28 -0600, Vic Smith wrote:

lateral movement allowed by bad bearing let's
the cable escape the spool. If one side is spooling
the cable differently ... you get a cocked door.

That was it!

The bad bearing must have caused the cocked door!

Thanks for the advice & diagnostic help.

Here's a picture of the completed setup:
http://www3.picturepush.com/photo/a/...g/12049826.jpg