All good points but I now realize the real issue is the bronze has been almost completely worn off the face of the washer (I can see traces of it in the cold light of day). This is probably a blessing in disguise - I was wondering why the flywheel mating surface wasn't scored. Will definitely need a new thrust washer and will try to figure out the thickness calculation tonight - I understand they come in three thicknesses.
Also, I am wondering if I put the RMS in far enough - left it out about 1mm and maybe that's why the crank was binding when I torqued the flywheel bolts. Don't worry, will definitely buy new bolts.
Sorry if this is a bit tedious - it's all been covered in ADV many times, I'm sure. This stuff is nerve racking for hobbyists like me.
One measly toaster