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I had my starter repaired and since then it has broken two cast iron nose cones. The reputable rebuilder says it bench tests fine and is working correctly. I tend to believe them, because they rebuild starters and alternators for many of the mechanics here in Vegas. I am at a loss as to what may be happening. If anyone has any ideas, they would be very much appreciated. This is getting costly. Thanks.

First thing I'd do is to check the flywheel for run-out and the condition of the ring gear.

Also make sure the starter is torqued down tight enough so it is rocking when it engages and causing the nose cone edge to come into contact with the ring gear.

Also are you sure you have to correct starter for your motor? There were a could of different designs, so wonder if the wrong one can bring the nose cone two close to the ring gear.

Also are you running 6v or 12v?