Hi Simon, yeah 99% certain I got everyting sitting nice and flush, in the heel, glue was squeezed out both front and rear at the heel. The fit side to side was not tight and slight side to side movement when at correct scale length.

I reckon as I have movement even though slight the glue joint wont be hard to break apart. As far as the neck and heel go pretty much all clear of any coating and just raw timber, was a little overlap less thn 10mm

Maybe dodgy batch of glue.

As far as the plate goes yeah would need shorter screws, particulaly at the back, the fronts would just hit the fret board at a guess, easy enough to get shorter screws. I think I shall pull the strings off and have a good look at it and solutions, very frustrating, so close to being finished.