OK, my back is telling me to call it quits for the day. I had a couple PM's asking for some clarification on routing your own baffle so I thought I'd add a couple quick pics. There are some other tutorials floating around here too I believe.
To add to a couple of the pics I posted earlier in the thread.
Clamp the wg down to the cut piece (I put a screw in each corner to secure it), and hold the router firmly against the wg while making the cut. You'll end up with this. You need to make sure you are using a 1/4" bit for this to work.
You will then take your piece that you just cut out and attach it to what will be your template. This is what you'll end up with. I would recommend using a piece of 1/8" hardboard as your template. Why? We'll get to that in a bit. You can see my template underneath.
I chose to cut my template out of an 1/8" piece of hardboard that was the exact dimension as my baffle. This would allow me to quickly go from speaker to speaker without having to measure over and over, and know that it was centered on the money.
This is what your template cut should look like afterwards. As you can see there is exactly a 1/4" gap all the way around the wg.
Here is where the router guides come into play. I picked mine up from Infinity tools. They will only work on router bases with 1-3/16" center holes. Those would include Makita, Dewalt, Milwaukee, and of course Porter Cable. Bosch requires an adapter as well as Skil and Ridgid.
Here is what it looks like with the guide in place.
Here is why I recommend using a 1/8" in backer for the template. The guide hangs down 1/8" below the router base, which just happens to sit almost flush with the 1/8" backer board. You can use 1/2 or 3/4" material, you'll just need to be more careful as the router will tend to tip in a bit more.
This is tough to see, but if you look closely, just to the left of the guide you can see my backer board that the guide rides up against. I started with a guide that was 1/16" smaller than 3/4" as I was looking for a really snug fit. Well due to mfg tolerances of the wg's this required a bunch of sanding to get it to fit so on the next two I went with the 3/4" guide which gives you about 1/16" all the way around for easier fitment and a little margin of error. With the 3/4" guide on, your router bit is pushed out 1/4" from the template, which as we remember, was 1/4" larger than the wg. Pretty sweet. When installing on top of the baffle you want to cut, remember that you will need to set the template a 1/4" lower than where your final cut will be.