So what we know so far doesn't make sense. You don't even have to take the flight will off to check the key just take the nut and the washer off and you can look right there to see if it's twisted or not or if the two rectangular slots are lined.
The top plastic fingers are only there for The recoil assembly to catch so that has nothing to do with it running.
If the key was right the first time which I thought I read it was then it would have made no difference with you taking off the flywheel and making a new key for it and putting it back together etc so my thought is it wasn't right to begin with.
Regardless, glad you got it running..