That's a lot. I'm not positive I know what exactly to do, I don't want to manipulate the fork, I'm not that level yet. I have a new fork coming that'll be here Weds I think. In the mean time I'll send pictures of the fork and bottom of the balance.
Have you checked all the pivots for wear?
Did you check them all for proper end shake?
Did you install a new mainspring and use the proper braking grease in the barrel?
Does the barrel arbor have proper end shake in the barrel, and the barrel have proper end shake in the movement?
Is there any wear in the main plate where the barrel arbor sits, or in the bushing on the barrel bridge?
Was there any damage inside the barrel where the arbor mounts, or any wear on the walls of the barrel drum?
Any corrosion in any of the pinions?
Is the balance spring flat, and not dished or angled up on one side?
These are all very basic things that need to be checked and any issues rectified
before you start any work on pallet forks or changing balance staffs, etc.. When this sort of issue happens, people tend to focus on the escapement and balance, but the fact that the rest of train spins without the pallet fork in place doesn't really confirm that all the other important things have been dealt with properly.