I haven't read all the posts in this thread, so don't know if someone
has already sent this link:

http://science.discovery.com/videos/how-its-made/#fbid=UKGt4uDMKcw

One of the videos on this How It's Made page features Estwing hammers.
To get to the episode, you'll need to scroll down to "Hammer Time" and
click on it.   You'll probably also have to endure a couple of
15-second commercials.  Attaching the washers is at the very end of
the video.  You'll be able to see what they look like and how they're
cut.  No surprise that the final step in mass production involves a
machine whose multi-functions might be difficult to emulate at home.
FWIW.

Chuck Myers

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