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That is why Mike suggested you try sizing the brass without the expander plug and check bullet fit. It could be your dies are properly sizing the brass, but the oversize expander plug is opening them too much.

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This is easy to tell when you size the case.
Some of my dies require quite a bit of force on the return stroke which tells me that the die body is sizing the neck to a smaller OD than the expander plug and the neck thickness of the case combined.
Kind of makes me want to take a cerrosafe cast of some of my dies and do a direct comparison with my correlating chamber cast. To my mind, the ideal would be to size the case with only the die body and ditch the expander altogether.

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