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From your description it sounds like the pickguard doesn't seat fully when in place? Is this what you said?
If so, is the rout shielded with conductive paint or copper? Or is the entire pickguard foiled?
I had an issue with the tone pot once (acting as a volume knob) and everything was wired correctly and ohmed out correctly (no blown cap). Sometimes while playing I'd get some static suddenly and a mild pop etc. What it turned out to be was the lead from the cap brushing against the copper shielding. Not constantly, but would be impacted by vibration of playing etc. The hard part is this only happened while the p/g was in place because otherwise everything was fine.
Anyway, long story short, could it be something like this? (since you mentioned the p/g doesn't seem to seat).
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