I wanted to piggyback on your thread instead of starting my own as I'm having a saddle issue with a recently acquired Old Smoothie (I actually owned it previously and bought it back from a co-worker - long story!). I received the bass last Friday and decided to clean it up and restring it. I removed the strings first. As I looked at the saddles, I noticed that they weren't parallel to the bridge. I realize that some like to angle their saddles, but I'm not one of them. With the strings off, I was having a whale of time turning some of the set screws, especially on the G. I was using the proper 1/16 hex wrench. As I attempted to turn one of the set screws on the G, I heard it crack! I immediately pulled the saddle off to discover that the set screw was indeed cracked but it also was stuck in the middle of the saddle. So it was not at the end of its adjustment either way.
I then attempted to adjust the other set screws. Some were easier to turn than others. I pulled all of the saddles to inspect the screws and found that I could easily turn all of them with my fingers, but when they were on the bridge (again, no strings on the bass), it was difficult to turn some of them. As I recall when looking at the saddles as they contacted the bridge, they looked as though they were pitched slightly forward. I assume this is a part of the design and within spec, but it seemed that the slight forward pitch was causing difficulty in turning some of the screws.
Anyway, I removed all of the set screws to inspect them and to soak them in some oil (along with the saddles) and I ventured to Home Depot to get a few replacements. I found 6-32 screws of both sizes (as has been described in this thread, the A and D saddles utilize longer screws than the E and G) and purchased a bunch of extras. When I got home, I reassembled the saddles and set their height by eyeballing them before reattaching them to the intonation screws. I have to say, I was pretty darn close because after I restrung the bass, my action was almost exactly where I wanted it. I'm glad, too, because I still found the set screws (after lubrication) to be somewhat difficult to turn. I even used two different hex wrenches to make sure that my original one wasn't rounding off.
I currently have the bass at my luthiers to have him cut a new nut as the strings I'm using have smaller gauges and they were rattling a bit in the nut slots. My main concern is having to make any future action adjustments. I guess if I keep the same strings on (and I most likely will since I'm having a new nut cut for those specific gauges), I won't have to make any adjustments, but it's a bit frustrating to know that I may revisit this problem some day. I contacted EBMM via e-mail to attempt to describe the issue and I'm waiting to hear back.