« on: December 15, 2013, 09:07:03 AM »
If I understood what you are asking, you are right. Using a router on plywood will be ugly as sin no matter how fast the blade is spinning or how slow you go with the cut. You will get chipping; but even if you didn't the shaped edge would look nasty and wouldn't evenly stain.
Plywood is often used as a non-shaped panel though. One just routes an edge on the rails and stiles that the plywood panel sits in. So really one only needs to use solid wood on the frame of the doors. To use solid panels would be an upgrade, but if you are looking to save money go with plywood.
Also, I'm not sure I would attempt the project with a router (handheld), but would try to find a shaper (a table version of a router) that I could use. Just a thought to avoid ruining a bunch of material because you can't secure it well enough.