Exactly how did you make the hinge mortise?
The only way I'd do it is with a router and a hinge template. Then I
use a corner chisel (if hinge is aquared) and a centering drill bit to
do pilot holes for the hinge. Get some scrap wood and practice before
doing it on a new door slab! You can make sure you got the depth
setting right on your practice before doing it on the real thing.
Chisteling it out by hand doesn't work very well. On my 1950 house
I've been filling them in with DAP plastic wood and redoing them with
my router as I redo the house. Carful measuring is a must when placing
the router template.

And I used a cheap Harbor Freight trim router, even this one:
http://www.harborfreight.com/cpi/cta...emnumber=44914
currenty on sale for $20 wil do.

Use metal templates for the router. I bought them off eBay. I really
hate the plastic ones! The ones I use look like this:

http://www.hammerzone.com/archives/d...g/drinc17a.jpg

In fact that whole Hammerzone site should be required reading for you.