Originally Posted by TMcG
I'd absolutely go this route, without question. I can't imagine creating the little jigs and templates you'd need to make for your router, not to mention all the chiseling and sanding needed to make everything fit. Your time is worth more than $100 - $150 and I'd think you'd be happier with the final product (nothing implied about your woodworking skills, of course!).
I like that foam idea if I needed to cut on the floor.
Like he said above the baffle comes with the kit. It's CNC cut and very nice. I agree that is a must have.
But the box I would cut myself. For sure. I hate to be the one to disagree but that's just me.
It's so easy to cut a box, it's square cuts. And the side of the speakers means it's small enough to manage on the table saw and use the fence. Plus he has a track saw. No doubt about it I would cut myself. Compared to this stupid closet I've been building making a speaker box is simple stuff.
One reason I would make my own would be to substitute the 1/2" MDF with 3/4" MDF and make the box more rigid. I actually find it easier and stronger to use anyways, especially if you are brad nailing. 1/2" is tight to fit a brad in, but 3/4" is much easier to get it right. This avoids all that mess with clamps and hassle.
Since you have a track saw, I would buy a sheet of MDF. Have the store rip it a few times with intelligent dimensions for the speakers you are building. For instance when I was making a 24" cubed sub I had HD cut it into 24" strips. MDF is sized 49x97 I think anyways so you can make cuts and still get full pieces. Just take a look at the width of the speakers you are building and have them rip it like an inch over that. Just so it's easy to carry and manage by yourself when you get home. If not, I guess you could use that track saw
Carry full sheets just sucks though, especially inside or down stairs.
Once you get the peices cut per the cut list, there is a trick you can do to make them ultra perfect. What I did was rip everything with my hand saw but about an 1/4 inch larger than I needed. You could do this with track saw if big pieces. Then I set up the table saw fence and ran every piece with that dimension through it at the same time without adjusting the fence. I did this for every dimension and side that was not a factory edge and the result was I ended up with identical peices in size that all fit perfectly. If you cut pieces one at a time or whatever you'll have very small variances (like the width of the blade) but small variances are not good when making perfect boxes. The other trick is to just adjust the fence just a "CH" (use imagination) closer and run all the pieces again through to ensure they are the exact same lengths.
Provided you can do something like that, or that you just make accurate cuts it's very easy to do. I did not order the flat packs for my speakers and I do not regret doing it. If you can build a theater you can build a speaker box. It's relatively easy to make straight cuts and small rectangles of wood with a table saw if you can use the fence.