Sanding birch ply.

[YNWaN]

A router with a profile cutter (a bearing guide above the bit) will probably give the most accurate finish.
You do need a straight edge to follow thought.

Clamp the straight edge on top the board you want to finish, but set it back a mm or so, the bearing runs against the straight edge whilst the cutter trims the edge of the board below.

Yes, I agree and use this method often - particularly where complex curves need to be recreated (though I use an inverted router which makes life slightly easier, but makes no difference to the finish).

[walpurgis]

I have to find a way of cutting mitred ends on long panels using a short table saw. It will require some thought, but I'll do it one way or another .

[oceanobsession]

I use 6 inch sticky sanding pads different grit grade used for car paint etc , then use a long plane screw the blade up and stick the sanding discs to the side , lye the plane flat on a bench with the wood you want to get straight you can clamp the wood , ive done this with 40mm solid oak to straiten it up
hope this helps phil.

[mikmas]

Check out my latest speaker build using panels of birch ply.
All were cut using a hand saw and finished on a belt sander with 80 grit fitted. Dead straight and true, no gaps in those joints.
I used a straight edge and builders square to check as I went.
http://www.jkwynn.co.uk/Project_Imag...ev_Cabinet.pdf

I tried a circular saw on the first cut, it ripped it up, I was amazed how good I got with a hand saw, in terms of straight and square.

Fabulous work - like the use of layers to avoid tedious router stuff

Must admit I'm a great fan of the handsaw approach nowadays - and you get plenty of exercise .....