I had the issue with the S/C pulley when first installed and added the additional shim to bring it to the corrected gap. I have had no other issues after adding the shim. I can't say what might be wrong with any one else's pulley but the install is very straight forward so I can;t imagine it is a problem with the basic install.
The shim I used was the largest added to the 1 that was already on the S/C when removed so the gap is with in tolerances at this time and working as designed.