When you add it all up using plywood isn't going to save you much money, as you will have to spend a good bit on sealing the plywood, and thick plywood isn't nearly as cheap as the thin stuff.
If you go with ply I would recommend 1/2" thick ply That has been sealed very well as plywood is usually very porous.
I highly recommend that you look into the economy line of racks sold by AnimalPlastics and/or the racks sold by RBI
AP: http://www.animalplastics.com
RBI: http://www.reptilebasics.com/reptile-rack-systems
A professionally made rack will be much lighter than a home made rack, and in most cases will be better made (since they use computer controlled routers to make all of the parts with extreme precision)
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