MDF can be had easily in 5x8', 5x10', 6x12' size sheets in 1" thickness, but 1.25" I am not so sure, I know 40mm can be had but that is 1.5"+. I don't know your suppliers bulk costs, but I have purchased a few large MDF sheets to make ping-pong tables for friends, and $/sqft was 160%+ compared to 4x8'.
Regarding, partial vs. full kits I think it would be a good idea to price production costs + shipping for both and see what the market will bare. For East Coaster's, or people with no tools it may be worth the cost for a full kit. If you get setup with a good forwarder, LTL freight can be relatively cheap.
The other option would be to remove one of the back pieces, and include one side, and also include 1 of each tunnel piece in place of one of the braces, thereby including both baffles and at least one copy of each unique part. This way a person with some double-sided tape and a router with flush trim bit could dupe all the parts.
The other thing I see is the tunnel pieces and sides, which I would imagine is not cost effective to CNC, if your supplier has a gang rip and crosscut saw he could blow those pieces out much cheaper and faster. All that CNC machine time for such simple parts may raise costs unnecessarily.
Originally Posted by Erich H
It is. Maybe the sealed boxes though. I think it makes sense to get a price on the smaller sealed first because it only needs 2 pieces of ply per pair. Plus, I think the CNC guy can get the thicker wood for the baffle and at 40" tall, he could cut a lot of thick baffles from 1 sheet of thick wood. The ported boxes are taller and you couldn't get nearly as many from one sheet.
I'll drop off the designs on Monday or Tuesday when I go to their shop.
Maybe I'll show him both designs and see what he thinks.
Don't you guys think the kits should be all or nothing flat packs?