What is the " consensus" on resizing fired brass for the AR?
It
needs to be done!
Gas guns need resized brass more than bolt guns if you expect them to perform properly when feeding from a magazine. If all you want to do is single-load, it's still important - but in different ways.
What's important in the first case (sorry, pun intended here!) is that your sizing die be of a design (interior profile) that properly sizes brass for
your rifle's chamber.
So you say new brass works best even with a vastly shorter headspace than what you aim for when resizing? Any particular brand work better than others? Have you tried pushing your shoulders back to match that new brass dimension? (I can't recommend this as normal practice though as by doing this you're severely overworking upper case bodies & shoulders.)
New brass is short so it'll fit almost any chamber profile. It may have a larger shoulder diameter than what your sizing die gives you though, otherwise you might find yourself suffering from mis- or non-firing rounds due to cases being too far forward when the firing pin strikes primers.
Conversely, even with headspace properly dimensioned for
your chamber witn
your die there may be other issues from sizing that end up giving you cases that aren't aligning properly once chambered.
First off I'd suggest you remove your bolt's extractor and ejector then set up your sizing die to run some once-fired brass. Does unloaded & unsized brass chamber under recoil spring pressure alone? If it does, you need only size your necks to hold bullets.
If it doesn't, work your die down by 1/8th turns until brass chambers easily. Minimum sizing's what your after, not some arbitrary number.
You using the supplied expander ball too? Probably necessary if your sizing die's not a bushing style, as most have neck portions of far too small a diameter thus mandating use of the expander ball. That combo overworks brass too, which is a bad thing for accuracy and case life.