There is a very noticeable loss of volume when the tone stack is active vs. when it is bypassed, since you're not losing signal through the passive tone controls. But it shouldn't be extreme, and your description of the volume going through a minimum at the tone control midpoint doesn't sound normal at all.
Please provide a set of photos--they need to be LARGE, well-lit, well-focused shots of BOTH sides of the PCB and all of the jack and switch wiring. You can post them to a publicly accessible hosting site and display them here or post them directly here using the forum's file attachment function (found below the main posting text box). If you use the latter, know that there is a 1 Mb size limit for image files, so it may be necessary to reduce their dimensions or their color depth to get them below that size limit. Any of a number of image editing applications will allow you to do this. I often recommend
IrfanView for this purpose, since it is free and very easy to use.
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