We study the approximability of envy-free up to any item (EFX) allocations for indivisible chores under complement-free cost functions. Our main result is an instance with $255$ agents and $764$ chores with binary XOS cost functions, in which no $α$-EFX allocation exists for any $1\leα<2$. The construction is based on a combinatorial expansion property of binary labels, obtained using Sidon sets and Reed--Solomon codes. We formalize the main result in Lean 4. We also study the special case of three agents. We construct a six-chore instance with monotone subadditive cost functions for which no $α$-EFX allocation exists for any $1\leα< 2^{1/3}$, and a six-chore instance with monotone submodular cost functions for which no $α$-EFX allocation exists for any $1\leα<20/19$. These constructions are obtained by refining the original counterexample of \cite{CS24}.

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