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... if I put more ethernet cards in the desktop could I essentially create a router?
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Sure! After all a router is a small special purpose computer, often with an included ethernet switch and wireless access point, that can be bought for $30 - $200 (less when on sale or when a rebate is available). No reason at all that you can't get or develop the right software and hardware and use a $1,000 - $3,000 general purpose computer as a router.
EDIT: Actually, if you enable ICS the computer is already acting as a very simple router and Dhcp server. You just have far fewer options and settings than you do with even a cheap brand name router.