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We are remodeling our kitchen and I am doing ALL the work myself. Right now I am building the shaker style cabinet doors. They are maple frames with MDF centers.

The issue is that the rails on some of the doors are sitting slightly higher than the stiles because of variances in my router setups as i build parts for ~50ish doors, drawers and cover panels. The distance of the misalignment is somewhere around .030"-.050", so less than 1/16".

Aside from scraping those doors and making new ones, what would be the best option for leveling them out using tools/equipment that a DIY'er might have or could reasonably invest in?

Pictures to follow.
 

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That difference is too much to fix with hand tools. The finished surface will not look absolutely (by eye) flat plane from several angles. Large drum roll sander can fix it but expensive. I think your better way is to start over. I don't think furniture building grade table routers are in the rental stores. Plan things so you are cutting all same parts without changing the router settings. Make a sample and use it to set the router and keep checking the settings.
 

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Use a random orbital sander with 150 grit and sand the high spot down and carry it back 3-4". Use a satin finish and you won't see it. Next time, test fit first before glue-up and make any adjustments then. I prefer to use a dado set on my table saw when doing Shaker style doors, in my experience, more accurate.
Mike Hawkins
 
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