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Re: very frustrated
If you bought a rebuilt starter, the bendix or solenoid could be bad or marginal from the beginning. Typically, rebuilders test everything before, during and after assembly. But bad parts do get by the tests, especially if the rebuilder doesn't have quality in mind.
A weak bendix spring or solenoid could cause the problems you have. Also check the voltage going to the solenoid from the ignition switch. A voltage drop could cause issues that would look like a bad part.
As for shimming... Yes, you could cut up the shim. Or you could just find a washer the right thickness. But if you just have to shim one bolt, I'd be looking at why that is. Chevy starters shouldn't have to be shimmed at all. That's just how they were all designed. If you were working on a Ford, That would be another story! (Many Ford starters come with shim kits in the box. Hmmmm..... Just another reason to own Chevys?) Can you get any clear pics of the starter bolts and where/why you have to shim? If we could all see what's going on, it might be easier to diagnose the problem and get your Burb back where it belongs...On the road.
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