On the cartridges where you could get a handloaded round to seat with force, could you notice any marks on the bullets? In the past, I've found that COAL doesn't mean a lot (with regards to closing an action) so much as does the ogive of the bullet. A bullet with a squatty tip doesn't have to be as long as cartridge with a slimmer bullet tip to give grief when closing the action.
Did you try to chamber any of the brass after trimming and after neck-sizing but BEFORE charging and seating a bullet? That might help track down what's going on.
Seems hard to imagine how a piece of brass that was fired and ejected smoothly from this rifle wouldn't then also chamber the same piece of brass later.
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