This is a cross post from the Wisdom of the Hands, but can be used with large boxes. Butt hinges have been a craftsman's headache for years, decades, centuries. There is the hard way, using, ruler, square and marking gauge for layout, and chisels for carefully cutting the hinge mortise. It is demanding work, and each one offers innumerable opportunities to screw up. Then there is my technique that makes it easy and is featured in the April issue of Fine Woodworking that arrived in today's mail. A simple shop made jig allows you to rout hinge mortise after hinge mortise, each in perfect depth and position. I wrote the article and Matt Kenny, editor, took the photos of my process in the Taunton wood shop.
I believe my techniques for installing butt hinges are my most original contributions to the techniques used in woodworking. I use the router table and story stick on projects small enough to fit on the table, and then this simple router jig for large projects. The April issue of Fine Woodworking will be arriving in the magazine section of your favorite book store this week.