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So I thought I would conclude this in the unlikely case somebody else has suffered this problem.
It ended up being a loose ring gear on the factory flywheel. Honestly, until I looked into flywheel construction in general, I didnt even realize the ribg gear was a seperate piece, figured it was machined in. But makes sense, they are clearly hardened steel vs cast iron flywheel. Anyhoo, the ring gear was so loose it both moved in and out, contacting the starter pinion and the lower exposed bellhousing mount surface. It also began to spin on the flywheel! I installed a brand new 86 take off oem flywheel and she is finally as perfect as a 36000 mile can be.
So if you have grinding/contact noises and issues on a lower mileage frs/86/brz and have confirmed its not the clutch or tob, have wear on the starter pinion, and after some time develope starting issues, consider your flywheel ring gear!
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