Here are photos of the 3 cuft model. There's a couple options on this model due to it's size and how it fits on a sheet of Baltic birch. This sort of complicates things for this particular box size and I can't make up my mind what to do. Inner baffle on both options would of course be Baltic.
We can either have 2 full length cross braces, and the outer baffle gets made from mdf.
Or we can have 1 full length brace, then 2 smaller braces that still lock the top and bottom to the adjacent panels. Using the 2 smaller braces would allow enough room on the sheet to get the outer baffle made from Baltic birch.
Which would you prefer? Here are pictures of both, keep in mind, these panels are just sitting up with no tape or clamps.
This bracing system allows the outer baffle to be Baltic:
This bracing system takes up extra space on the sheet, the baffle would probably be mdf so we don't have to dip into the 2nd sheet of Baltic:
I'm inclined to think it makes more sense to get the outer baffles made from mdf. That way a good number of boxes can be ordered with a 14" cutout to fit a lot of woofers. Then the mdf baffles could be cut later to recess specific woofers. The only problem is that this would likely add about $8 to each kit. I think the mdf baffle would also be easier to paint.
If we go with the smaller braces, the second baffle layer fits on the same sheet. Sounds like a no brainer. But obviously the recessed outer baffle would then have to be cut at the same time, so I might be able to get that done to fit about 5 woofer sizes. If someone wanted a different woofer recess, it would likely be mdf.Edited by Erich H - 11/11/12 at 12:31pm