Been there before. Mine broke on the first start of a fresh engine rebuild and i about dumped my pants when i heard all the commotion from the starter nose breaking. It turned out to be aligned wrong. Had a new nose installed on the starter and then made extra, extra sure to pay special attention to the alignment of the starter when reinstalling. Still, i seem to attract this type of "bug" no matter how careful i am. Some of us are just gifted....join the club