Is your spacer in behind the carrier there? Mine fell out once and I didn't notice, made a mess.
Renthal lightweight front. Did chain. Talon rear sprocket. Had identical setup on my gen1post a pic of your installed front sprocket.
Also what brand of chain is it?
Did you check the width of the master link?Chain 8.1mm at narrowest point
I use a lock washer in lieu of the cotter pin for my woodcraft axle sliders. They will not go on without the cotter pin out. Their kit comes with the washer. But yes the nut does not move. I have checked the torque spec many times.If all as reported then out of alignment. Have to make certain that the alignment lines are lined up WHILE you can look through the AXLE. Looking thru the axle tells you to get your line of sight straight so that you don't dork the alignment. A baseline as we say in the science club. Do this on BOTH SIDES and THEN check after you tighten the axle nut as our Kawa corp likes the cotter key holes lined up. I noticed a long time ago that when I tighten past the torque specs to line up those stupid holes the RIGHT side goes OUT FARTHER than the left. And that is what you did assuming all variables that you mentioned are correct.
Interestingly, the only reason why I know any of the above is because of the Met rr rear tire grips far better than any other tire used. rr does not spin, or spins far less. But the cheap sprockets hate that met rr. I'll report all of this later when I put enough time on the vortex hardened sprocs. Up until the last few weeks I've ran nothing but spinning rear tires on the rear for years. Sprockets were happy, I guess.
I don't use the cotter pin, btw. and that nut has yet to move.