I went through similar troubles in lining up my '36 front end. I was working with a re-cored original '36 passenger car rad, but I think the shop remounted the side mounts off by a very small amount which throws everything out of kilter. I ended up having to do a small amount of selective grinding where there was interference at the sides of the grille, and also I had to fabricate my own hood ornament mount which needed to be about 3/8 inch lower than the original. After that, and a few tweeks with all the bolts finger tight, I was able to make it respectable. After tightening everything up, it is not perfect but it does not bind on opening the hood and there are no huge gaps anywhere like it was on the first install attempts.
Persistence will pay off, I fooled with this one for many hours.
By the way, almost forgot - if you are working with a repro grille your troubles will be multiplied by a factor of about 5. At first I was working with a repro grille that I bought in the mid-80's, and later on I was lucky enough to find a decent original grille that solved A LOT of the alignment problems.
Good luck.