De-sky,
are you talking about the width of the cut being too big and the ca hinge sliding sideways? If so this will hurt nothing.

Now if the heigth of the slot is off and the hinge just falls in and out you are going to have to do something to fill the gap.

Its a personnal thing but I do not use the H9 hinges that get sent out with the arf's. I normally use the Great Planes material that comes in sheets and cut them 1" x 1" or I use the ProSouth blue hinge material, if I can find some that does not luck cut too crooked.

If the gap is just too big in width then when you ca the hinge in place you ca the wood back together. The gap should be the heigth of an xacto blade cut.

Ed M.