Well, I keep messin’ with it and getting closer. Funny thing is is that I found my 1/4" Whiteside setup bar to be only 0.2480", a couple of thousandths shy of 1/4". Luckily my DIY 1/4" stock/stick also measures same, so I guess it all works out the same once you/me figures out to adjust ;-)

Anyway, this box-joint is finally looking better and more evenly spaced:

ALL THINGS SAID… I am still happy that I ordered the Incra Box-Joint Jig. 8-) Adjusting with a BFH is just morally wrong IMO!… ;-)

HorizontalMike