I make quite a few boxes, jewelry, etc. I use the table saw and set the
blade 1/16" shy of going through the sides. Then I use a small handsaw
(Dozuki) to finish the cut. A slight a amount of sanding on the cut and you
have a perfect fit. Not my idea, I learned it from Doug Stowe who has some
pretty darn good books on making boxes.
Al in rainy Longview, WA