I've had this happen twice for me.
The first time was during multiplayer where one of my buddies activated the waypoint portal near the Chapel door. When I walked past the Gale spawn, he didnt come out. So i went through that one, out the Chapel one, and back to the Gale Spawn and then he appeared.
This also happened in single player where the above didn't work at all. I reloaded to the beach initial autosave and he spawned afterward.
