Always had the same issue. Tried surfacing the washers and banjo with 400 grit on a glass plate but that didn't work either. Now I smear RTV (lots will hate this but only a smear!) on all surfaces. Much of it gets wiped off but it works. Slight risk I agree but as long as it's not put on heavy works for me.
I paint the washers with Permatex Aviation form-a-gasket. In fact, I've done that with most of the washers, whether copper or aluminum. Stopped just about all the leaks.
Go to your local auto parts dealer and order two 1" id aluminum washers with a bonded rubber inner. We include 2 with every oil tank we send out, which are aluminum, but they work with the stock tank also, cost about three bucks for both.
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