Just a thought...
Try measuring the case wall thickness at the point where your bullets seat.
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Could be (I don't have any on hand to test) that the Federal AE walls are thicker. Multiply that by 2 and you might be getting too much crimp compared to other brass which might cause the cases to deform ?????
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Actually that could very well be the problem, I did some Lapua Megashock JHP a few weeks ago using FC AE brass but these had the stepped in base on the projectile.
The FMJs im trying to use dont have this so as you say it might be very very tight.
I might keep these and build up a few hundred before I mess with my dies.
Currently ive got 1500 rounds of Speer Brass in waiting (loaded ready to shoot). and only 600 FC AE.