it is because you can omit zeros from the left side of a number (001 = 01 = 1) and private keys are simply numbers and the encoder converts the number to bytes then to hexadecimal, if the bytes count are smaller than 32 there will be smaller number of hex characters and sometimes encoders don't pad the string properly so you can end up with 64, 63, 62,.... and even 1 character.
What happened and why is this? I am also not able to convert this 63 hexadecimal character private key into a WIF format either.
it shouldn't matter, you are just changing the encoding of your number.
for example private key 123:
int: 123
hex: 7b
hex with padding: 000000000000000000000000000000000000000000000000000000000000007b
WIF: KwDiBf89QgGbjEhKnhXJuH7LrciVrZi3qYjgd9M7rFU86d9GNkvq
however depending on what tool you are using to make the conversion between different encodings they may not accept strings that are not fixed length and you may have to pad it with zeros.