Richie,
It seems that you may have a couple of issues going on at once. Most likely, the biggest issue is probably a short or open somewhere. Shorts can sometimes happen when you close the chassis because all the pots and pcb and everything can get kind of squished together causing something to be connected that shouldn’t be connected. Check to make sure the backs of the pots aren’t shorting against anything, possibly through the insulation paper (make sure there are no punctures in it). Also, this type of issue can be caused by bad solder joints that aren’t making good connection. Please check and re-flow the solder joints on the board (pay close attention to the solder joints on the pots).
When you get the solder joints and connections situated, that may solve all of your problems. But i am curious how calibration mode worked for you. Did one side or the other not work?
-Brach