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That was my problem too. When I called to order, they actually aske me if it was ok if they cut it! Good customer service there if you ask me!

$25 for 18" of NiAg rod and 100 washers seems high. I got my NiAg rod from Texas Knifemakers supply. I think Texasknife.com. If you call to place your order, tell them they can cut it short to fit in...

Yep yep and yep. Microfasteners is a great place. Get stainless and brass in all the 1/16" sizes if you plan on doing very many at all.

Hobby Lobby, Lowes, Home Depot (maybe, haven't confirmed...