Ok, so I got this job, for a Jimmy Vaughan Strat. I get it home, there's almost no relief in the neck. I adjust the truss rod, bringing the neck dead flat. Jig it up in my neck jig, set my dial indicators, lock my rods, take the strings off, loosen the truss rod, using the pull strap and working the neck around, I get it zero'd back. Everything looks good, so I use my steel beam with sandpaper to take kiss off the fret tops, found a few high spots and a few low spots, everything looks good, maybe I've taken off .002, but not more than that. I tape off at the 7th fret and file a sand a slight drop away at the 17-21st frets. So, I crown the frets, polish out, string up the guitar and tighten the truss rod back dead flat. The action is .080 at the 12th fret on the low e, and .075 at the high e, there's still a good amount of buzz at the second, third, and fourth frets.
I start adding relief, it doesn't start to really clean up until there.s about .020 of relief. That's way too much.
The customer comes over and checks it out, he's not happy, and neither am I.
So, back in the neck jig. Do all my adjusting, this time, just in case it's the double stick tape holding the sandpaper giving slightly, I use my diamond coated sharpening stone. This finds a little high spot at the 9th and 10th frets, but other than that, the frets are dead flat. Recrown and polish the frets, string back up, still some buzz. I have to add at least .010 of relief, and have the action same as before to get this thing to play without too much buzz, but there's still buzz. Sounds like it is buzzing on the frets right above where I'm fretting, not up high on the neck. I take my straight edge rocker and check, I can't find a rock anywhere on the fret board. Use my straight edge, there's still the fall away.
Everything is as it should be. I just don't get it.
There's only one more thing to try, I've been using the same strings that came with it, I was going to put new strings on before setting the intonation, but I noticed some slight flat spots on the d string, probably because the guy has a death grip, I think. So, before I do anything else, I'm going to swap out strings, probably tomorrow morning, and see what I get.
If that doesn't work, does anyone have any other suggestions?