I've been a woodworker for 30 years, and I have a shop-built box joint jig for my table saw that works just fine. I decided to try doing box joints on my dovetail jig, but I'm having a couple of problems that I just can't seem to work around.
The most important issue is the length of the fingers/slots on the templates. With stock more than about a half-inch thick there isn't enough finger/slot length to let the bit make a straight-on entry and cut all the way through both pieces of stock. I can make the complete cut only by adjusting the template fore-and-aft, which makes it practically impossible to make clean cuts.
Am I doing something wrong, or am I severely limited to relatively thin stock?