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Part of the problem is that the bolt-on neck was designed for a Fender-style tight fitting neck pocket with an end wall, and part of it is that the mahogany-type neck wood is too soft.
"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
This is a very good advise , and one to remember for future if I come across any of the bolt on guitars with such issue .
Is it possible that the deformation has occurred in the bridge area rather than the neck pocket?
This has almost solved the problems for most strings , apart from low E .
However saddles are still where they were .
The fact you could get a 3mm block in there and still attach the neck shows it was definitely too loose. I would try pinning it in place too next time the neck is off
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"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
The intonation is correct now , though I haven't adjusted saddles at all ,so they are still at max position .
It may not look fantastic but , Tbh I am happy it actually works alright and I'll be able to use that guitar .
I am going to stick this thread to original Hondo as well as post some other photos of electrics etc that's now completed too .
Not sure why intonation it's so much off , but I guess it's an old and cheap guitar , so things could go sideways ?