Hi Stephen
There is no correlation between the leak you had from the pressurestat coupling and the HX /piston /lever, portafilter circuit. They are two totally isolated systems. Could the leak have been due to excessive load being exerted on the lever, physically causing strain on the boiler mount system and that pressurestat coupling? The resulting leak was boiler water, not water from the top holding tank through to portafilter. By altering the grind/tamp, you were effectively reducing the strain you were putting on the entire machine.
I found that wrapping the ball joint and thread of the pressurestat inlet in PTFE tape stopped leaks when using reasonable force, but can still leak with a tight basket.
Do you mean the pressurestat coupling "can leak with a tight basket" or a leak is occurring from the hole under the grouphead or down the side of the boiler from the grouphead? If the latter is the case then the o'ring at the top of the piston cylinder #16 is failing.