Thanks McCreed and Simon,

The gap at the neck pocket is about 2-3mm, but its hidden by the fret board so a little hard to see. PBG said it should be fine as is, but I think I will have a crack at reshaping the neck to fit the pocket over the weekend. With this, you would reshape the neck to fit the pocket right?

I had a chat to the tech support at Colorspec today. He was very helpful.

To paint the body, he recommended prepping the body as for any wood (grain filling etc), followed by a normal water based wood primer - Roller onto the body. Followed by sanding smooth to about 400 grit. The sanding sounds like fun...

After than, a light coat of their primer, slight rub with 600 grit, base coat (2-3 coats) and clear. He recommended no more than about 6 coats of clear total. He said 4 coats should come up nicely, but if more was desired a slight rub back after 4 coats with 1500 grit before a max of 2 more clear coats. It seemed to me he was more concerned around their clear adding a slight yellow tinge to the paint if too many layers were added - Maybe this is something I am after..

Im guessing that I will need to leave a week or two after grain filling before priming, then another week or two after priming before spraying to make sure there is no water trapped in the paint / wood - Would that be about right?

For the headstock, he said their clear SHOULD bond to the bare wood, but if it was his project he wouldn't attempt it.

He recommended starting with normal water based or acrylic wood lacquer on the back of the neck, once that has been applied then having a go at the front of the headstock in their base / clear system (per above). For the joint of the lacquer and their clear, he said after the colour has been applied to create a false edge so their clear coat overlaps the lacquer which should bond well and can be polished back to form an invisble line.

@McCreed I know I have seen it in one of your previous posts, but can acrylic lacquer over the top of a poly clear? Mainly just looking at the joint between the front face of the headstock and the natural finish on the back and sides.

Thanks,
J