Mark & Juanita wrote:

Any help would be appreciated. As a pre-emptive, the answer, "just chop
them by hand" is not an answer I'm seeking -- I'm really trying to figure
out why this machine is not working as advertised.

No solution, but feel your pain.

As much as I like the jig, I continually fight with it when attempting
to do a "production run" of drawer sides for dozens of drawers at a time.

I've pretty well accepted that there are simply too many parameters,
from stock, to router, to jig, to obtain the kind of ideal CONSISTENCY
in that situation, from first to last.

But, I do remember my "pre-jig" days, and the alternative was worse ...

On the current project I'm toying with going with the Multi-Router just
to see if the "consistency", from first to last in a many part run,
improves.

--
www.e-woodshop.net
Last update: 10/22/08
KarlC@ (the obvious)