Could I make them from 15mm ply and double up the front baffle to 30mm? I'd adjust the internal pieces for the port to make it work and keep the internal volume as close as possible.
I can flush mount the horn and driver then another front would be stiffer (if that would make any difference).
I was thinking of making the internal braces from 2 pieces of ply (an interference fit) and cutting lots of large holes in them. One above the woofer and one below (or cut to fit around it). Is this too much or will it alter the panel resonance frequency too much?
I'm assuming you prefer MDF for it's lack of large voids, consistency of density and ability to absorb sound waves more than ply?
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