Do people use rubber or neoprene washers for bolting the drivers?
anyone know where to get black bolts and screws?

It seems like for mounting the (heavy) baffle to the front panel, more screws is better than less (words to live by :^) ) but how many is enough? 8? 12? 16?

EZ

For attaching the baffle to the enclosure, I would use threaded inserts, if you have enough wood.

In both cases, use locktite (or equivalent).

A reasonable hardware store ought to have black bolts. Ask the dude about it, they might be stashed away somewhere out of sight.

For sealing purposes, there are a number of different gasket materials you can use. If the joint is two flat surfaces, a cardboard gasket works well and it is easy to install and remove. Silicon and caulking materials form a good seal, but they often stain wood and are harder to clean and remove.

Loctite is a liquid that dries to rubber-like consistency, whenever you have metal-to-metal contact it helps prevent loosening due to vibration. The medium-strength stuff unscrews pretty easily, it's not permanent.

Best of luck with your project. I'll bet it will sound fantastic.

Yup, those little black allen bolts are cool, I use 'em too.

If you don't have a removable side, getting to the nuts on the back can be a bit of a pain, though. On my small fullrangers, I need to get at them through the top-firing vent.