Here's some pix of my progress thus far. I know my woodworking skills are nowhere near that of most on this forum but the boxes will be behind my screen so it shouldn't really matter.
I'm standing on a step ladder looking down at the box laying on its side. Remember that is an 18" driver and it looks much bigger in person!
I haven't siliconed anything yet, just glued and screwed the braces and box sides so far. The port will be cut smaller once the total volume is determined.
My port hole didn't come out quite as good as I would have liked. I personally don't own a router but I borrowed a buddy's Ryobi but I couldn't come up with a good reliable way to cut circles. I tried a piece of clear acrylic I had laying around as a circle jig. I started ok but the router bit melted or cut into the acrylic and I went off course. I tried with a piece of 1/4" plywood I had laying around, making sure only the shaft would touch the wood but it still didn't work for me. The hole ended up getting elongated and burnt! My hats off to you wood workers! I ended up using my cheapo Black and Decker jig saw which naturally didn't cut perfect circles but it should be ok since it will be out of sight. Do you think turbulence will create a problem with my not so smooth roundover job? Also, I could only find a 5/8" roundover bit at the local big box stores so that's what I used. Oh well, hopefully it will still sound good.
The last photo shows my 10.5' wide screen where the two boxes will go behind.
-Tom A.