So where was this piece of plastic exactly? In the regulator itself? What you're describing was definitely a solenoid issue, so fixing something in the regulator shouldn't change anything unless it was directly interfering with the regulator.
You should never use your needle valve to turn off a regulator. It's bad for the needle valve and could potentially damage it.
Also, your pressure drop is normal. The pressure on that gauge should stay the same until the tank is basically empty, as the presence of liquid CO2 in the tank keeps the pressure the same. The changes in that gauge should only change based on the actual temperature of the tank.