I think it is a rarity for a butch, upon close inspection, not to be recognized as such. No Adam's Apple, wrist size, voice, lack of facial hair, the "softness" of the face - particularly the jaw. IMO, if you know what to look for, you're gonna know 99.99% of the time. Of course this doesn't include transmen on T, unless it's early on in their usage. After a few years on T with voice change, beard, change in jawline, body shifting, chest surgery if needed or well binded, and sometimes baldness, not a clue.
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