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Measure everything first though, whilst it's still together. If the measurements add up, something else is wrong.
If you have one, mount a trapeze tailpiece to the strap button hole and use it to test positioning before you drill. If you don't have one, make a string holder out of wood
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Downloaded the peterson strobe tuner app this morning and it looks like I can get it to around 2 cents sharp with very light finger pressure, and it's mainly the low E that is out, the rest aren't so bad.
Before doing anything drastic, I'm going to do some more playing. I may be able to live with it. I'm also going to try fettling the action down a touch, that could help a bit.
You can check for nut issues by putting a capo at the 1st, making sure open strings are in tune, and check intonation at the 13th.
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Bridge position was set before dressing the nut, so that may have caused the original issue.
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Found a 1/2 inch plug cutter, so cut plugs from the same mahogany and maple blanks that the body was cut from. Glued with titebond. redrilled and now it intonates properly.
Haven't decided what to do with the finish yet, think it's beyond drop filling. May try and patch it and relic as originally planned or just refin the top when I spray the next build.
Lots of lessons were learnt in this build!!
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Turns out, playing it a lot dings up the unplasticised nitro pretty rapidly. I had a band practice on Monday in a cold barn, it was about 3 degrees outside, then brought it in the warm house. It's now checked all over
...problem solved!
I think I'll now get the drop fill sorted on the bridge, give it a few more dings and some hot/cold cycles in the car boot on cold evenings. I also need to age the hardware, and it may finally be 'finished'.
overnights in the cold shouldn't be an issue for a solidbody electric, worse case is needing to re-do the set-up once checking has been achieved
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Before (and also new)
With Pickguard and poker chip
Ultimate target