Quoted from Gogdog:
Oh wait...after rereading your post...you are suggesting basically making a washer out of an old flipper plunger. I was thinking you were saying...taking that flipper plunger, cutting it to exact size to be used as the new coil plunger.
Anyway....the chunk you are talking about would still be able to 'fall over' in a coil sleeve. The #8 washers are a very close fit to the coil sleeve. In fact..probably tighter than a flipper plunger. Like this ->
However...after thinking about it...I believe this washer really is a good solution. When I put in a nut, it wasn't near as tight, so it could fall over and then when the plunger hit it, it wouldn't flip back over, also due to its hexagonal shape.
With the washer...its a tight fit so when it falls over, it stays in the center of the coil sleeve, and...I dont' think it can even fall completely on its side because the plunger will hit it. Plus...I just tested it by dropping the washer into this coil sleeve vertically...it always falls flat on its face.
Thus, anytime I move the PF vertically, yeah...the washer might turn...but as soon as I put the PF back down, the coil goes in a vertical position, the washer will then rest flat against the coil stop no problem.
Sounds like a good solution, but if you’re only talking a mm or two, I’d just bend the bracket.