Sounds like you have this about figured out, good deal.
Since you have to pull the starter to reinstall the shield anyway, put the starter through the hole in the shield on your workbench and make sure it sits flush on the starter and there is no interference. It could be pushing it in a little when installed.
If its sitting flush, I would try to put a little bow in it to the engine side. It should be pressed up against the back of the engine block when bolted up.