I'm using plywood because I want to stain the wood so the lines and texture are still visible. I'll be using sanded plywood because it doesn't have chunks missing from the edges like the standard sheets. Its about $45 a sheet. in Canada.
The box will be made of horizontal cross sections of 3/4 " plywood stacked on top of each other and glued together. The main bend in the box is easy as that is on the same plane of the pattern cut into the plywood. The curve around the driver gets a bit trickier as it on an opposite plane. Essentially I will have to widen the pattern 5/16" as I approach the widest part of the circle. Widening the tube part of the pattern will increase the area before it intersects the main box giving it that blend as it approachs the rear of the box. That will leave me with a rough pattern of the tube around the driver, from there its a lot of sanding. Right now i'm leaning toward the bottom design with the square back half of the box.
There won't be any pics until after the driver arrives. It should be here next week. I need to actually see this thing and physically use it as I make my patterns. This design will take lots of careful thought...measure 6 times and cut once in this case.
I'm leaning towards design 1 because its 1.5" shorter than design 2 but still the same volume. But I've been looking at these so much my perspective might be out of wack; I would appreciate your opinions on which design you like better 1 or 2?