The problem is that even with a no-hassle refund process some customers will still call their credit card company and ask for a chargeback because it's a proces

The problem is that even with a no-hassle refund process some customers will still call their credit card company and ask for a chargeback because it's a process they're familiar with and it's easier for them to do than to go through any kind of custom process you've built for them. I imagine after dealing with customer support BS enough times your goodwill is eroded and you're just going to choose the path of least resistance for yourself.