Are you lubing the inside of the case neck before running it through the sizing die? If not the expander may be stretching the shoulder enough to prevent chambering.
And I assume you're using a FL sizing die and not a neck sizer?
I never used a form die when converting 30-06 and similar brass to 7.65x53mm. I just lubed the cases good inside and out, ran them through an RCBS FL sizing die, rough trimmed, annealed, final sized/trimmed and loaded. Never had any not chamber or give any other troubles. I'm still loading some that I made up 25 years ago.
I preferred Remington or Winchester cases, Federal and military brass was thicker and sometimes required neck reaming.Information
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