Very small grommets keep splitting I've been trying to put some very small grommets, marked size #000, into t-shirts. Since they're going to be resting directly against skin, they need to not split, since splitting creates sharp edges. Unfortunately, my efforts so far have (almost) all resulted in split grommets.

I've tried a handheld grommet punch that had to be hit with a hammer. Then, after some initial success at the store, was convinced that I just had to buy the smoother-acting grommet spreader that had a big handle you pulled down to mash the grommet into place. Once I got it home, I was back to split grommets. (What was different in the store?)

What should I be doing to stop splitting my grommets? Do I need to be buying grommets made from a different, more ductile material? (And if so, what material would that be?) Is there a different technique for installing the grommets that I'm somehow missing?
If there is nothing technically wrong with the grommets then there is probably not enough material in their grip when you are attaching them. Thus they over crimp and split. 

You could try adding a washer shaped bit of cloth that matches the diameter of the ring of the grommet to add more bulk, or try not squeezing them as hard. Using a washer of extra fabric will help them last longer as there will be less stress on the t-shirt material at the grommet.