Per @John Morris request here is an alternative box joint jig, using a router, no fine tuning needed, and allows variable width keys, if desired.

Nice tip Keith! And thanks for separating your idea and tip, definitely deserves a topic of it's own. You could do this for narrow pins all the way up to larger finger joints, correct? As long as you have the router bits to accommodate?

Also, how the Orion work out, still have it?

Looks simple enough. The only thing is that the actual finger and slot openings are slightly rounded where on a tablesaw setup they are 90°.

4 minutes ago, MrRick said:

Looks simple enough. The only thing is that the actual finger and slot openings are slightly rounded where on a tablesaw setup they are 90°.

The router bit clears the wood being cut, into the center strip, so they are square, not rounded. The guide strips are inset from the center piece, You can see the cut-out on the center piece for the first few cuts and the uncut ones on the right in the photo.

Edited February 5Feb 5 by kmealy

35 minutes ago, John Morris said:

Nice tip Keith! And thanks for separating your idea and tip, definitely deserves a topic of it's own. You could do this for narrow pins all the way up to larger finger joints, correct? As long as you have the router bits to accommodate?

Also, how the Orion work out, still have it?

Yes, the finger width must be at least as wide as the router bit you're using. I think my smallest jig cuts 1/2" fingers and the largest 7/8.

I still have the moisture meter, but have not had a need to use it yet. But I have some air-dried cherry and walnut in the shed that I'll use it on some day.

Edited February 5Feb 5 by kmealy

Looks like that one might be easier to use as well.