GM/VolvoHeretic,
I made up my mind to go with Octagon design unless you all think otherwise. Early next week I will have an opportunity to get some ply so, I will start on that part - lumber mart caries only 5X5 sheets but I can get 4X8 from HD or Lowe's. I can get 1-5/16" dowel for bracing miter joints and go for the right bracing/insulation inside once GM finalizes.
Glue choice - PL400/Titebond Wood Glue. Silicone Sealant?
Gasket - Neoprene - any particular size? For keeping front baffle removable, should I have this on both front baffle and the inside frame?
I assume any wooden screws will do fine.
The top/bottom board
From VolvoHertic - "The top and bottom panels if made with just a single sheet of plywood should have a 1/4"x3/4" rabbet routed in so that the side panels have something to lean against. You could also make the base and cap out of two layers with the outer most being full dimension and the second being 3/4" smaller and that could be made out of mdf."
Is it required to have either rabbet round or the additional 3/4" smaller board inside? Anyways the top/bottom board will be screwed/glued on the side panels. If required, I think additional 3/4" smaller board inside sounds like a good option.
I can get started on these initial steps.
Thank you,
Sri
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