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You are doing the right things. This is why it's important to measure each motor. I'd be willing to accept as little as 1mm for a street motor (factory spec for an early S motor is .8mm). If you can't get that by tweeking the timing then you'll need to do something like the shimming or have the pistons cut for clearance. The best way is to cut the pistons if they have a thick enough dome. I think the minimum you want is 5mm thick after the cut (Not sure about this number but the right number is in Bruce Anderson's book).
-Andy
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72 Carrera RS replica, Spec 911 racer
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