Believe it or not, real Baltic birch is pretty close to the weight of mdf. It is lighter, but on the larger boxes, it's not as much as I used to think it would be.
The CNC company told me that real Baltic is only available in 5'x5' sheets. I've heard this a few times before as well. But there are companies out there that swear they have 4'x8' sheets. I should go buy one of each and compare them.
I had pricing last year for some 4 cu ft Baltic enclosures, but the price was pretty high. I posted it somewhere and think it was over $130 before packing material and Paypal fees. The double thick shipping boxes are about $5 each, a sheet of thick foam would be another $1.50 or so. Price would likely be around $140 when all was said and done. I could probably get them to cut a smaller order of 50 if it was put in with another order. I'd certainly consider that, but if memory serves me correctly, the box was a little under 4 cu ft because that's about all you can get from a 5'x5' sheet with a double baffle. Now if the enclosure used a piece of mdf for the outer baffle, then it might help get a larger box.
There is an obvious problem though. What woofer would we get the box built around? There's just too many options. Changing the woofer hole means they have to switch programs which I'm sure would add to the cost. Their machine will cut 2 separate 5x5 sheets in one program, so 25 for one and 25 for another might not be a problem.
I was hoping this thread would help decide on what box sizes to go with what woofers and narrow it down, but it's been all over the place.
That makes it difficult for me to know exactly what to do because I'm not a subwoofer designer. When someone says they're waiting for the 2.75 cu ft box for a 15", sadly I can't do much with that info. The MFW style baskets are different from the Dayton RS. TC Sounds are also different from the others. Basically nothing really matches up very nice. So there's really no way for me to make a 2.75 cu ft box for a 15" woofer because it could be made 20 different ways.
What made all other past flat pack designs so easy was because the designer said "This is exactly what the box should be". Boom, project done. I can do that with no problem at all. But guessing is very difficult. If at the beginning of the thread I knew we needed this, this, and this, for certain woofers the project would have been done very quickly.