In order to save money and a little weight, the MDF was given up in favor of some very high quality 3/4" birch plywood. One sheet of plywood was cut into two 38.5" long pieces in order to cut the 8 10.5" x 38.5" pieces necessary for the front back and sides of the boxes. This was done using a tablesaw set up for making such large cuts. The tops and bottoms of the boxes were then cut from the remaining wood.

The baffles were marked for the drivers, and the holes for the woofers were cut using a jig saw with a down cutting blade. The holes for the tweeters and the ports were cut using a 3" hole saw and finished with the jig saw. The tweeter hole had to be trimmed to accommodate the terminals and the port tube hole had to be enlarged slightly.

The enclosures were then partially assembled using wood glue and brads for the front, back, and sides. The tops were then installed using wood glue and screws, though the screws were removed once the glue had dried. The crossovers were to be attached to the bottom of the enclosures, and being my first design, I wasn't sure enough of them to have them permanently installed. This led me to decide to make the bottoms of the enclosures removable. They are attached with #10 3 1/2" screws and sealed with a gasket of vinyl foam tape.

The edges of the enclosure, I routed using a 3/4" radius bit down to about 4" from the bottom. The edges were all sanded and wood filler was used to smooth the seams.

Since I did not want to spend a lot of time on finishing the wood, I decided to paint the boxes. I used latex primer and paint and applied the paint with a hand brush to give them a rough kind of finish that will be easy to touch up, but relatively durable. They are painted what I will call an alarming color of red that matches no furniture I have ever seen. Good art isn't supposed to match your furniture.

The inside of the box is lined with 2" thick polyfill-like material on the top, back and sides down to about 8" above the crossover board. If I had to do it again, I might order the egg crate foam and use that, but the stuff I used was free and works pretty well. If anything, the boxes could use just a little more stuffing.