Don't let them "fix" it under warranty!!! They'll add an oversized bridge! arghhhh! ugghhhh....
The fix is to move the saddle back as far as it -can- go. It will get close. Note that you never noticed before, so it's not -that- critical, is it? Now, if you're ear is fussy, move it as far back as possible, angle it back 8 or 120 degrees, and in the new bridge(oh yeah, new bridge..), angle the pin holes, also. This will leave you a decent and not excessive break angle, and move the saddle to just about perfect. If you still need some further compensation, and you truly can hear it(be honest with yourself, now), then you can move the nut up closer to the first fret, either with a ledge, or by shaving 1/64th or so from the end of the fretboard.
The best time to gain some intonation was at the neck set time, where shims could have bee made(and made invisible) to move the neck up(away from the saddle). This, in combination to the bridge work, brings them in perfectly. And again, 100% reversible. No oversized bridge(and resulting oversized bare spot on the top), no new bridge plate and holes in the top.
Intonation can really kill volume, believe or not, because it completely screws the overtones, of which make up a large percentage of sound.
Spoon feed time...
here's my fix for a tubby, quiet 70's D-28/D-35. In order of work, as budget allows.
a) Fix intonation(work with existing bridge if owner can't afford next step) b) replace bridge with intonated(read above re: saddle and pin holes) BRW or MadRW bridge with long saddle c) bone pins, unslotted, slotted bridge, tight fitting strings d) replace gigantic RW plate with small maple e) bone nut if the original isn't ivory. If ivory, leave be if possible(depends on setup). f) replace tuners with Waverly, including plugging old holes and re-cutting them properly(stepped holes). g) shave finger braces(only!) h) Tune up and enjoy. Find banjo player; proceed to submit banjo player to attitude adjustment.
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