Few more questions:
1. What do most people use to attach the driver (tempest X) with? I read one guy's blog where he was using 2'' 10-24 machine screws with t-nuts attached on the back side. I found the 10-24 machine screws easy enough at home depot but the t-nuts were nowhere to be found however I haven't checked with other hardware stores yet.
Hey... good ole #8 woodscrews 1" long work great. You don't need to do the t-nut route. I hate t-nuts because they are a pain to work with. They don't really offer any benefit outside of the fact they might save you from stripping the MDF if you get a little crazy with the drill. Even if you do strip them, you can always rotate the driver and try again.
2. I've got a Bosh Brad Nailer and I think I can shoot 1'' brads. I was wondering if this would be adequate for securing the cutouts to the tube along with some sort of construction adhesive such as Liquid Nails?
Liquid Nails Construction Adhesive holds great. You have to hold the tube in place long enough for it to dry but once it sets, you are golden. Be careful with the stuff because it doesn't clean up. If you get it on something it stays.
3. Does it matter where the port comes out at? I've seen designs where the port comes out the bottom, but mostly I've seen them come out the top. I'd think coming out the top would be optimal.
It matters but there is little you can do to predict exactly how it is going to interact without measurements that you won't have. Just make sure you have plenty of clearance no matter where you put it and don't stress.
4. Looking for suggestions on leg mounts...I'm not totally in love with the 4'' lag bolt suggestion. I've seen some stainless steel legs at Lowes that are part of a create-a-shelve package but I haven't investigated enough to see if that would work very well or not. I think they come in 4'' and 8'' sections. Not totally sure they can take the weight either because I'm sure they are not solid steel.
I saw some good wood legs with studs in Home Depot. They where not cheap, maybe $5 each but they gave enough clearance for down-firing. I'd just recommend combing the HD & Lowes for a solution.
Going deer hunting all next week so another couple weeks and I should be building this bad boy. Got my Tempest X in on Friday...it sure looks to be a beast. Still I'd wager they're isn't much difference in the weight between it and my SVS PB10. I had to replace that SVS driver one time and it seemed awfully heavy for a 10'' driver.
Weight doesn't necessarily tell you what you get. There is some correlation because the steel in the motor is the most expensive part of the driver. You try to conserve what you use to keep shipping weight low also. But... it isn't necessarily a performance indicator.