Thread: Help and advice required please

I've always had a problem with hinges and hinge mortices, but it all became a lot easier by using "story Sticks" or "measuring Sticks". The measurements are transferred from the stick to the lid and carcass.
There is also an "easy option", by using barrel hinges.

What Noel said is correct, it is very difficult without a measuring stick or story stick. Measure where you want the hinge to fit on the carcase of the box. You only need to measure on one side on the carcase and then transfer this measurement to the story stick..Make sure you mark the stick on both sides. The story stick has to be the exact same length as your box. when you have the measurement on the stick for one side of the box, just flip the stick over and then from the marking on the story stick, transfer this to the other side of the box carcase. This method will make sure that your hinges are going to be the same distance from the ends of the box. Same with the lid of the box. assuming the lid is the same size as the box carcase and is to fit flush.
Simply mark off the location of the hinges with the story stick and after marking the location of the hinge, flip the stick over and mark the other end of the lid. At this stage locations of the hinges should line up perfectly.

You need to make up a simple jig for your router and use stop blocks to prevent the router cutting past the ends of the hinge markings on the lid and the box carcase. Setting the correct distance from the fence and the depth of your router is critical here to create the exact location for the hinges. You only need to do this once for each end ot the box and the lid. Sounds more complex than it really is but once you get the hang of it, its not that hard.You will need to chisel the corners of the cut out hinge recesses to square them up for the hinge.

The simplest way of course is to fit external hinges and these can be quite decorative if you choose the right hinge and can add to the overall design of the box.

Another simple way is to use the hidden barrel hinge as Noel suggested. These cannot be seen from the outside of the box and are easy to fit if you use the method where you drill the correct size holes to accommodate the hinges before you cut the box open. Just make sure you drill the holes deep enough to accommodate the depth of the hinge in the carcase part of the box. after you cut the box open you will have the holes exactly in the correct spot for the hinges. The only thing with this idea is that you will have to fit a lid to the top half of the box so that it covers the hinge holes that will be visible from the top of the box. There are several ways this can be achieved but I will assume you know how to do that. Simple way is to just glue a piece of timber the exact size over the top half of the box covering the hinge holes. Unfortunately this method would not allow for movement of the timber so a more sophisticated method is probably a better idea.

If you want to fit the barrel hinges to the box after the box is cut open therefor drilling the holes from the underside of the top half of the box so that the holes are not showing from the top, then you will have to make up a simple jig to line up the holes for your drill press.

This method is prior assembling the box

Laying the two pieces side by side butt join wise and as John says transfer the the location markings across the two pieces attach the hinge after router/chiseling the mortise for the hinge. this should square the back edge

If all else is square

One of the big causes of this problem is the fact that most brass butt hinges aren't square. The first thing you need to do is square them. Also, number each leaf to show where abouts it will go, and enlarge the countersinks - they are never deep enough.
Set each hinge in the carcass using one screw only. The centre of the pin should be Very slightly outside the back of the box and above the back.
Sit the lid on top of the box, and carefully align all the corners & sides. With a marking knife, mark the locations of the hinges on the back of the lid. Remove the lid, and carefully chop out the recesses for the hinges. Set the hinges in the lid, again using just one screw. The close the lid and see how it sits.

If a corner needs to be pulled forward or back, do so by locating the next screw off-centre, either to the front or back. Think very carefully before you commit yourself. You can continue to adjust the location by positioning the screws, until they are all in.