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That's my measurement including the height of the fretboard since this bridge will sit close to flush with the fretboard.1.5" is thin?
I kinda feel like that's the max for thickness.
Yup, already been thinking about that too. The bridge itself is 16mm "wide". I think the only part of the insert that is a problem is that lip at the top, plus the threaded part has that knurled part at the base of it that matches that lip diameter. So you are correct, there may be a larger hole drilled at each end, it's just part of the joy of going this route I guess. I haven't fully committed yet, I guess there's still time to just fab a bridge out of a piece of brass stock or something. I dunno. I have massive reservations about trying to do that and actually get intonation remotely close.How much wider than the bridge are they? I'd be concerned that the route for the bridge will have extra space around it at the ends cause you have to sink the posts and sleeves into the body. Not sure how else you'd do it. Could you epoxy threaded sleeves into the bridge (inside the post holes)? Then just sink a brass plate in the body under it and get Allen head screws that thread in and press on the plate.
She made her own bridge from aloominoom bar stock, set at a slight angle. But she didn't cover the fabrication of it much, just a post showing it done and said "Got the bridge done". So basically an acoustic style bridge.Also, you'll be burying the TOM intonation screws... making something might be the best idea. What did @mapleglo do?
I'm not against that, but I don't know that I am smart enough to know how to get it angled correctly.
I've read a lot of stuff that basically says "intonation is scale length plus thickness of string". So if you have a .100 low E that one should intonate at 34.1". But, I've never actually put that to the test, and when I see guitars with saddles that move forward, it makes me pause.That ends up being easier than it sounds. Get your hands on a bass that's set up similarly (same scale length, same action/relief to what you want, set up with the same strings you'd like to use). Then measure the actual speaking length of each string and you know a starting point for where your saddle needs to be. If you're nervous about having enough adjustability, just make it from 1/4" wide stock and you'll be golden.