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Comments
Ian
Lowering my expectations has succeeded beyond my wildest dreams.
Find a guitar that you know is set up correctly i.e. doesn't take much pressure to hold down an open E or barre F, and doesn't raise the pitch of certain strings when fretting the chord. Do this technique on that guitar and you will get an idea of the small amount of clearance you are looking for over the 1st fret. As mentioned earlier, it doesn't take much filing or cutting in the slot to get the right height or to go too far. The same is true of filing down the underside of the nut, and removing it to do so isn't something I would necessarily recommend.
It's quite easy to chip out bits of the fretboard removing a nut, and if it has been glued in with more than two tiny dabs of glue you can end up pulling bits of wood from the nut rebate that remain stuck to the underside of the nut. You then have an uneven base for the nut and deepening it to make it level and square again can easily go wrong, or at the very least negate having removed the nut to file off a sliver from the base.
Saying that, this forum isn't without its fair share of good luthiers/techs
You don’t ‘need’ feeler gauges, but they can be helpful if you’re unsure what you’re looking for or how tiny the gap you want really is.
The gap should be around a quarter of the string diameter, or even less - as low as a tenth of it, ie between .001” on the plain E string up to about .010” on the low E at the outer ends of the range. (If .001” sounds too small or difficult to achieve without risking going too far, up to .010” can work OK for the thin strings too.)
From the description of the strings being hard to fret, I’m guessing it’s *miles* higher than this. If it is, cutting the nut correctly will make an enormous difference, almost hard to believe how much until you’ve played it before and after.
"Take these three items, some WD-40, a vise grip, and a roll of duct tape. Any man worth his salt can fix almost any problem with this stuff alone." - Walt Kowalski
"Only two things are infinite - the universe, and human stupidity. And I'm not sure about the universe." - Albert Einstein