I checked and double checked all the settings on my box jig to be absolutely sure nothing was wrong. Then did a test cut, everything fit exactly like I wanted. But.... if this makes a difference, the test cut was with the wood grain. The project piece was to be cut against the grain, I didn’t think it would make a difference, but it did. But I can not figure out why. I would think a box joint is the same regardless of which way it is cut, right? But nope it is much tighter, way to tight.