Am I correct in assuming that a gap of 0.004"-0.005" behind a portion of the saddle (when under string tension) is a very dangerous thing? I made a temporary saddle to put in my newest guitar while the original one is off to the guitar's builder to be copied (and raised a bit). I know the top profile isn't quite right and the shaping and polishing is crude but I must also have been a tiny bit inconsistent with its thickness. It seemed quite snug when I installed it but now a week or so later I can get a 0.004" feeler gauge behind it (between the back edge of the saddle and the bridge slot wall) for about the first inch or so of the treble end.
This is a cut-through saddle slot, old-fashioned like a Gibson, not glued in place. Bone saddle, ebony bridge. I think what changed since I installed the saddle is that I bumped the two unwound strings up from 0.012"/0.016" to 0.013"/0.017" and the humidity in my house has dropped to around 43-46% for the past couple days (down from around 50% when I installed the saddle). Will the bridge slot get wider if the humidity drops and the ebony shrinks a bit?
At any rate, I lowered the tension of the strings a whole step and I think tomorrow I'll remove them all together. I'm worried that any lack of perfect fit at all with a through-saddle might break the bridge.