#0 washer not fitting over 1/16 brass rod???

I went to the hardware store to pick up some 1/16th rod (brass was all they had), and some #0 ss washers. Well, here is my problem. #0 washers dont go over 1/16 brass rod. for the life of me, it would not fit. I tried numerous washers and numerous rods in that combo, on the off chance that maybe the first one (or two) I picked up was milled bad. no luck.
The next size up in washer is a #1. This seemed a scosh too loose, and I was concerned that when I peened the rod it might not spread enough to be secure... but I wasnt sure.
Everyone who has done a tutorial or post on pinning has always said 1/16 rod and #0 ss washers. so... what gives guys?
what am I missing here?

Any help is appreciated, as I plan to return to the hardware store tomorrow.

Does a 1/16th" drill bit fit into the washer? If not, you have some tight washers and may need to be reamed out?

If getting bulk washers at the corner hardware store they may not be sized true. I know everytime I come accross a new to me hardware store, I'll swing in to see what they have in 0 in hopes of getting a new outside diameter to stock, but sometimes the ID is not really sized correctly.

I've had nickel rod that is a little larger than the advertised 1/16. Personally haven't had that for brass, but that's possible too.

See if you can't tap the washer with a hammer over the end of the piece of rod, sometimes I have to do that, especially when using 1/16" NiAg rod, which seems to be a bit bigger diameter than 1/16" brass rod.

Sometimes when cutting or filing the face of a rod, I have to file the edges a little to get a washer to fit on. Try filing the edges a little to see if that helps.

I'm just trying to find a local source for #0 washers...... I hate the idea of ordering $4 of washers online, and paying $4 in shipping.....

As annoying as the shipping prices are from MF, I think you'll likely pay more for the washers locally. My advice is to order a lot of washers at a time to get your money's worth on the shipping. Or split an order with a friend.

I was paying $.19 each for #0 ss washer at my local hardware store (and that was a competative price). out of 20, I had ZERO fit the brass rod I bought. I ordered 100 washers (same size) from MicroFasteners. with shipping, it came to $6.20 (or $.062 each) saving me roughly 66%, even with shipping considered, PLUS, they fit over my brass rod just fine, no drilling of the washer or filing of the rod required anymore, saving me time.
Good deal, I'd say!!

A 2.5mm nail punch certainly helps getting snug fitting washers into place.

Just another though which has happened to me this week.

1.5mm is often used as a substitute for 1/16th and is sometimes sold as 1/16th. 1/16th is actually 1.58mm and the difference is pretty well undetectable by the naked eye.