I ran into this issue, and I believe it was caused by the plastic not being sufficiently liquid in the barrel, causing the feed screw (auger) to transfer torque through the thick plastic to the barrel; I don't think it has anything to do with the nozzle. Now, based on Tim's instructions, I let it get up to temperature (180), then wait another 15 minutes to let the heat saturate the plastic further down the barrel (i.e. further from the heating element and the thermister), and then it starts smoothly. Since then, no troubles.
Before, I was starting the motor as soon as the thermistor reached the target temperature, and I repeatedly had to rotate the barrel repeatedly to keep the feed hole at the top. And that's pretty irritating - you have to unscrew four bolts and hold the whole assembly together, rotate it 90 or 180 degrees, then bolt it back in place. And I think that's why I was having "washer" problems. After rotating the barrel and/or replacing the washers a few times, I am very happy waiting 15 minutes. Plenty of time to make a good cup of coffee, then come back and flip the motor on.