Dovetails would be easier, only because there are fewer, but why are you
even considering making speaker cabinets out of solid wood, when the
acoustic nod goes to particle material?

Box joints can be done on a router, though pieces as large as you mention
would require some handling equipment. It's not rocket science, just a
fence the size of the bit, spaced a bit's width (or a RCH less) from the
cutter. Each cut is referenced to the preceding, just as with tablesaw
jigs, but I have to believe moving a router through a clamped board beats
holding that same large board on a saw. No chisel necessary for any method
I'm aware of.

Personally, I'd use a rabbet/tenon joint on particleboard, then veneer.
Note that veneer does not have to be 1/20th of an inch thick. It could even
be what you resaw and smooth.

"Chris Berry" wrote in message
...
Hi all,
I'd like to know the most efficient way to make fairly large box joints
for
speaker cabinets without spending too much time doing it or a lot of money
on tools.
I do own a router (well two actually) that I usually use for finer work
and
edges but with all the templates I've seen, there's chisel work needed to
square up the joints afterwards.
Is there an easy way to set up a template that can handle this task so
that
I can use box joints for the sides (and back maybe) of the cabinet?
The pieces have edges up to 80 cm (32 inches) and are typically between
1/2"
and 3/4" thick birch ply.
I wouldn't mind using dovetails instead if it's any easier.
Thanks.
cb