Contemplating making a couple changes to the design, and would like some feedback. The plans call for constructing the front soffit prior to DW. I am still planning to do this. However, the plans also call for that front soffit to be 2 layers of 3/4" MDF, covered with 1/4" DW (all with GG between).
Couple of things concern me. Number one is the weight of that soffit. That is going to be one heavy mother. I understand wanting to put as much mass as possible between the sound and the ducts. Makes sense, but it seems like a bit of overkill to me, and I'm not real comfortable with that much weight. The second thing that concerns me is I would then cut two giant holes in that mass for the supplies that are directly open to the room. Planning to build custom duct boots similar to what Big and damelon did, but want feedback on an alternate plan.
The first part of the plan would be to move the location of the supplies from the front soffit to the side soffits.
Grilles would change from 4x36 to 6x24. Same overall area and I would still build the custom boots. The holes in the front soffit for the supplies would now be inside the side soffits, and not directly open to the room.
The second change would be the soffit construction itself. Instead of using 3/4"+3/4" MDF + 1/4" DW, I would use 3/4" MDF + 5/8" DW. Less overall mass, but also less weight which would make me feel a bit more relaxed. Also, I would be using 4 puck lights that would be recessed in the DW layer, but not in the MDF. Essentially I would be surface mounting them to the MDF and covering with the DW so the only penetrations would be small for the wires and sealed up.
Am I overthinking this? Is this a sane change to the original plan? Other thoughs?