Hi ijaein,
I'm not exactly sure what you're trying to do, but I am going to guess that you are making what we call (variously) a Strainer, Support or Stiffened frame that goes in the back of a moulding to strengthen it.
If that is the case, while the Hoffmann system can work, as you say - it is a lot of work because it requires precision.
Our solution is to use Hoffmann at the outside miters, and a
Pocket Hole system for the inner bars. You will find pocket holes to be quite a bit slower than a nailer but much faster than Hoffmann.
If you still want to use the Hoffman, there are a couple of ways that we've done them.
- Our initial method was to first assemble the outer frame with a strap clamp, then place the inner pieces in position and draw a line (or lines for multiples) across the joint. Then use the Centerline Marker on the Hoffmann machine to route on the lines. The downside is that use of the Centerline Marker is not terribly precise.
- We then introduced a couple of jigs for use with the perpendicular crossbars. Kind of hard to explain in words, but one was designed for the end of 2" wide crossbars - it had two parts, one that clamped into place on the machine and the other was a space to make the second route. The other was for the edge of the outside bars - this one clamped in place on the bar and had stops that referenced the outside of the machine so it would allow movement side-to-side in the same amount as the crossbars. I think I have video of it somewhere if you're interested in this route. However, it's not feasible (without some sort of modification for the angled pieces.
As I said, we've since gone to the pocket hole screw method.