I'm having the same issue with replacement calipers on an '80 TA. I could feel the new washers where stiffer, but never thought about being too hard to indent and seal. Might have to try the annealing process.
Thanks for the tips... 
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Mitch
1970 Chevelle SS
1966 Chevelle SS
1967 Camaro ss/rs
1938 Business coupe, street rod
2000 FXSTS, original owner, 13k miles
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