The way we do ports is to cut a hole that allows the tube to be inserted flush, then apply the veneer over that, covering the edge of the tube. We then paint the interior of the tube black. The plastic pre-made ducts are nice, easy to use, attractive and having radiused ends. But I always liked thick cardboard, as it is almost the same material the wood the cabinet is made from.As for the port diameter, 65mm is fine. If you were considering a 75mm or 80mm port, then I'd be concerned. But when going to 65mm, it's actually very close. To put this in perspective for people thinking in terms of Imperial measurements, the inside dimension of the one π speaker is 2.38", or 60mm. A 65mm port is 2.55", which is enough change that we need to modify the length to compensate. But it isn't a huge difference, and the substitution can be made with a proper offset.
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