Is it possible you have bits of rust or other foreign materials on the sealing faces? I have used hand cut washers made from brass shim stock to hold pressures to 6,000 psi, but the sealing surfaces were clean clean clean. Also look to see if the sealing surafces are completly flat and not warpped or dented.
Heating the copper washers to red and quenching in water will anneal them to dead soft. Copper works exactly opposite that of steel on quenching. It's cold work that hardens it, like squeezing them in a joint or bending. Either brass or copper washers should work for you in this case, just make a few flatness and cleanliness checks. One working and one not tells me a very small piece of something may be sitting between a seal surface and the brass washer.
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