That is really strange that you having that problem. Especially from the same lot of bullets. I see no problem with using a smaller gauge as long as you use the same gauge every time you load that make of bullet it will give a consistent measurement.
BTW I think the gauges are .257 and .264, so there should be a .007 difference in the diameter between the 2 gauges, but I bet they just get them close at .25 and .26 like your saying.
If you still have any loaded rounds from your first batch that chambers, I would measure one of those and then compare it to the one that won't chamber. Unless there is really something seriously wrong with the gauge, like dented or worn heavily.
Then just go over your math again. I've been known to make errors on my math many of times, that's why I usually make a dummy round with a specific bullet make I use and keep it as my reference for later on down the road if need be. I keep it with a small paper with its specs and the bullet manufacturer and weight. (It has no powder or primer) That would also been a good place to note what bullet comparator gauge you used to measure with also.
I'm interested to know if you don't mind just going over you math again and if you has a round that was loaded earlier and checked its numbers.
I have the same gauges and I'll pull both sets out and measure 2 different rounds and see if they give consistent numbers, I don't see why they wouldn't though.