Sorry I haven't had much time to work on the speaker design, I've been dealing with a couple of family medical emergencies. Here are my latest ideas on the boxes. These drawings show two front removable panels, a sub-baffle and a finished main baffle.
The sub-baffle would be attached to triangular gussets with wood screws spaced about 4" o.c. and the main baffle would attach to the sub-baffle with 3/4" aluminum angles along the perimeter and also at the speaker and port holes behind the cloth cover trim rings.
The aluminum angles would attach to the sides of the main baffle and the side of the cabinet with wood screws and the two angles would be bolted together with pan head bolts. I am thinking that the a sheet of thin laminate flooring foam underlayment sandwiched between the two panels would keep them from rattling. The angles would then be covered with wood quarter round.
I have not calculated the net volume but guess the depth of the box will have to be a little deeper, like maybe 28".
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