Can you flip the copper washer over? Can you rotate the positions of the contacts that touch the washer? That used to fix a lot of GM starters.

Tried flipping the washer, I also tried cleaning the faces to make sure they were clean, then I tried giving them a slight rub with some fine wet and dry.

The thing I don't get is if I push the contacts down with my pliers, the motor spins up no probs but as soon as the solenoid pulls it down, nothing. I wonder if its something mechanically stopping it spinning once the solenoid is energized?

I am heading out to the garage again after breakfast to investigate further.

I would thinkit was being stopped it would buzz and get hot fast....I bet the solenoid is just not pulling hard/far enough to get good contact.

Did you figure it out yet? I'm in a similar situation. Same click. My starter tests fine, I replaced the relay and I've had the battery charged. Next is to replace the positive cables. It's so frustrating.
I started it once. Drove to the store and then got back in it to go home and then it just clicked. It's the worst sound on the planet.

If its an automatic, check the netural safety switch on the transmission,it could be bad