I've WBD prior to the 7% wash for years. There's little point in doing it the other way round as the recovered methanol is unusable. I'm still doing it with the titrated acid washes I'm currently trying.
The most logical explanation is an emulsion, which probably means excess soap, which more than likely means excess water somewhere in the process.
I had it recently where I made two distinctly dodgy batches and one of solid soap. I'd adopted a method of drying using ambient air, which worked fine in low humidity but failed miserably in damp weather. Try going right back to basics, meticulously dry the oil and do a HPT, check the SG of your methanol, try new KOH if necessary. Then before adding the 7% wash, take a sample and 7% wash that before going ahead with the main wash.