Just out of curiosity, have you tried rotating the needle or nozzle
during assembly (I know, not an easy feat) to see if the contact point
changes postion or even disappears?
Ryan, you mentioned that you replaced the nozzle & needle, but have
you tried replacing the nozzle cap and/or the needle packing screw?
Reason I ask is they seem to have a direct bearing/association with the
parts in question.
Regarding the off center of the nozzle through the nozzle cap (touching) effecting the quality of the paint job - yes and no.
Under high pressure it probably won't be noticable.
Under lower pressure it "might" be.
Run some test patterns under a low air pressure setting to see if there is any ill atomization or spray pattern effects.
I had a larger spray gun for autobody work that had a similar problem and it never effected the paintjob.
Just my
worth.