A belated Merry Christmas to anyone who happens by!
And a belated update.
After gluing the baffle on Big Ma, next up was to use a belt sander (and palm sander) to trim and fit the edges smooth to the box
I then decided to add extra bracing, the additional bracing pieces
And with the extra bracing glued in (marked with green tape)
Then cut a 2 7/8" hole for the connector, and used a 3/8" round-over, and plugged the hole from the inside
And I leave you all with a question: I am thinking about cutting round-overs on the horizontal edges (from the baffle to the back panel?
Here are some test cuts on a dummy box, what do you think, cut the round-overs, or leave square/sharp edges?