I'm working on an end table right now and I am going to do half blind on the front of the drawer and through on the rear. Anyway, I messed around with some scrap to figure out how to use the jig (just bought it a few weeks ago) and the scrap came out great (first try on HB and 3rd try on TD). Problem is, I cut my first HB for the actual drawer yesterday (both tail pieces and one side of the front for the pins) and they don't fit. The only adjustments you can make according to the book is the depth of fit (too shallow or too deep -- you move the template in our out to compensate). But that's not my problem, when I start to set the tails in the pin sockets (excuse my misuse of terminology if I've botched that) the tails get crushed going in (their just a bit too wide). But I've looked through the book and considered what I can change and I can't think of a thing. I even put the pieces back in the jig and ran the router over them again to see if there'd be any new wood cut -- nope, the bit didn't even touch anything. Ugh. I didn't mess with the fingers once they were set and flipped them over for the pin side and that worked fine.
Help!! Other than paring the tails down with my chisel (not interested in that really) I can't think of how to fix this or more importantly what went wrong. Anyone with experience that can point out my mistake would be greatly appreciated.