DISCLAIMER: I am a complete idiot, no need to take notice
In your position, I would start at the basics, and try and see whats going wrong, presuming Wez's suggestion of scratching off the volume pot makes grounding easier, start by wiring one pickup straight to jack, then volume, then do it with other pickup, seperately, then try and sort out the switch afterwards. That way atleast you know it is possible that everything can work, and may isolate a dud component, or maybe a pot that has been overheated.
Think I would wire the tones up last.
To restore confidence... I heard VH only put a vol in his frankenstrat as he didn't have the complete knowledge of tone wiring :P