These are the dimensions that I ended with on my 2 Pi towers. The material is 3/4 Birch-faced MDF. The port, which I moved to the front, is of course 3/4 long and 4 5/8 round.I started with the intention of having a professional cabinetmaker pre-cut all the pieces for me, but for various reasons I won't go into I decided instead to have a nearby lumber yard make the rough cuts for me. I did the rest myself with simple handtools -- in a third-floor apartment of all places. Thus the odd dimensions.
Right now they are clamped together. Fiberglass installed but no bracing yet. Still, they sound wonderful!