To make things come out right, the die needs to be turned another 1/4-1/2 turn against the shell holder. There should be a bit of an over-camming action when you cycle the case to be resized. This is caused by flex in the press and shows that it is getting the full resizing effect.
Isn't that the procedure to set up any FL sizing die? I've never seen anything different.
My experience leads me to believe its because of the inconsistencies with brass dimensions and the nickel platting thickness. I've run into the same situation every time I load nickel. Matter of fact I just ran into the same issue a few months ago with my new 308. The only cases I could find/get were nickel platted
The case are standard sized brass with platting. The nickel plating makes the dimension of the neck just a skosh thicker. Consequently when you run one through the die, the neck is sized from the outside, making the inside diameter slightly smaller than with a standard brass case would be... when you pull the case back out it hits the expander ball and it takes more force to pull
some (due to inconsistencies) of the cases through, and consequently stretches the case slightly more than some. The extra force pulls the shoulder length out of spec, causing them to be tight fitting, or not fit. Since you sized them twice, you stretched them twice... its much easier to stretch a nickel case than to press/size one. Nickel cases are nice, but not my preferred type for loading.
The 7mm head spaces off the rim, but you can get them to head space off the shoulder... which you are, hence the reason for them not chambering.
my method... I size and then check to see that they chamber. The ones that don't, I toss. I suppose you could turn the necks, but I've never tried to neck turn a nickel platted case, not sure you could get the cutter to bite?