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I’ve transplanted a complete PRS CU22 wiring loom into a tele bitsa just altering the 5 way rotary for a 5 way blade. I've wired lots of guitars, lots of times over lots of years.
When I fired up the completed guitar all was well except the volume pot didn't completely kill the volume. Assuming a dodgy pot I replaced it with an old PRS spare but still had the same problem. Just in case I’d made a wiring gaff I disconnected the tone circuit and the treble bleed cap leaving just the hot from the 5 way to the left pot lug and the wiper to the output jack.
Unbelievably the problem was still there except lowering the volume now dulls the tone too.
In desperation I stuck in a brand new 250k pot but the problem still exists.
As I left for work this morning I had the Dragon pups feeding a 5 way switch, the hot from the switch to the left pot lug and the wiper to the output jack. Operation of the pot just slightly reduces the volume.
Just in case I had some bizarre earth / pickup coil configuration going on I cut the hot wire from the switch whilst playing and that finally killed the volume.
Is there something that my addled brain is missing here?
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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
"Just because I don't care, doesn't mean I don't understand." - Homer Simpson
Ideally you need to bend over just the top part of the terminal at a right angle using pliers so you don't stress the rivet on the track board.
You can usually fix damaged ones by squeezing the rivet hard with pliers as well.
"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
"Just because I don't care, doesn't mean I don't understand." - Homer Simpson