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Tips for installing a volume knob?

My metal version had the same construction difference as yours, I believe. The action often baffled me. Sometimes I thought it was a little too high; sometimes there was that "detuned two steps and now things feel a little floppy" kind of vibe going on. Again - after crossing the vintage threshold, those few problems didn't seem to be much of an issue anymore.

Ah, good to know. This one's been pretty stable. Not roadworn yet, hence the puzzling action. At this point, maybe the wood just needs to breathe...:D
 
The OP has a tricky problem that only years of (ab)use can mellow down. My advice is to take the unit out as much as possible and let her vent out the harsh overtones in the bright autumn chill.

I have two vintage ones and sometimes I couldn't store both of them in the same room. I used the strategy outlined above, became a soccer coach, and had little problem with either after this. Now, I hear the older unit is starting to crunch out little units all by itself, after having moved in with a matching model (not in my house any more, for years). We'll see if the squeal problem persists in the 3rd Gen model...
 
I have sunburst (MIA w/ some Mexican parts), and a blonde (MIA).

The sunburst has shown sings of volume control issues as she has gotten older (14, now), but for the most part, has been pretty well behaved. I have a feeling, however, that the issues will continue to pop up more frerquently over the next 4-5 years.

The blonde has had lousy wiring and controls since I bought her, but the periods of squealing feedback and uncontrolled volume spikes have become less frequent and slightly more predictable over time. 8 years in, and things are working okay most days. I don't trust the wiring over the long-term, however.