Yeah I never use multiple passes for door parts on anything except maybe the deeper raised panel profiles. Really for those those I just use the shaper.
If your router is sized properly for the bits and the bits are quality you should not need multiple pases or even have to sand much if at all.
This is one area cheaper bits show their weakness. I use the cheap bits a lot, but for door parts use the best money can buy. There is substantial difference in quality of cut and the speed and depth at which you can make those cuts between when using quality bits. Pretty much for those type bits, door rail and stile and panel raisers you get what you pay for.
I would rather have better bits and a lower quality router than bad bits and a great router. I have found that the better more expensive bits for door making really do pay off in the end. If you can do one pass or even two instead of 3 or 4 passes you just saved a whole lot of money.
I still say making doors use a 3HP and up router with the best bits you can afford, that makes it a fun job instead of arduous.
Last edited by dovetail_65; 01-31-2011 at 08:20 PM.