Have you tried or considered a "loose tenon & mortise"? Cut the mortises as norm with the router but, the tenon, you use a round-over bit to make the edge match the mortise.
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Ken
"A VETERAN"
"Whether active duty, retired, national guard or reserve - is someone who, at one point in their life, wrote a blank check made payable to "The United States of America", for an amount of "up to and including my life". That is HONOR, and there are way too many people in this country who no longer understand it." -Author Unknown
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