In case you did not see the relies to you outer post here is my solution
Ok, with any jig that is this style, if your tails are being crushed during
assembly, you are cutting too deep. For looser fitting joints make a
shallower cut. Too loose, cut deeper.
The problem is that you are cutting too deep and this makes the slots too
narrow. If you raise the bit to cut shallower the slots will widen and the
tails will be narrower. When you get it just right always use this depth of
cut for "this" bit. If you buy another bit of the same size, start with
this depth setting and adjust from there.
And by the way... as you know now, you cannot reroute blind dove tails.
Once cut, that's it. Work on scraps until the fit is right.