Wood is not a perfect material to cut, carve, or rout. It also has it's own characteristics which makes it unique, including a little tear and chip out. Having a tube of wood filler handy saves many a project. If you have to, include, like Scottart does, a disclaimer about the individual qualities of wood, which makes each cut "unique". There will NOT be any two projects that look exactly alike. If somebody wants perfect and bland, than tell them to get molded plastic some place.
What you made is custom and personal, and minor flaws (which are noticeable probably only to you) make it more sentimental to the end user.
Don't get "sloppy", but don't be too hard on yourself, or you'll needlessly burn a lot of wood.
If you do a lot of painting than consider using something like Corafoam. It cuts as perfect as can be in one pass, is durable, and finishes great. But it has no grain and isn't cheap.
Last edited by honesttjohn; 07-01-2016 at 03:24 PM.