My wife (the artist in the family) is into transforming her photographs into three dimensional work. An award winning B&W photo of hers that was a close up of our old Victrola grille was her inspiration. Klipsch Heresy provided the grille mechanics (yes - pure plagerism). Here goes - I used 1/8th inch hardboard, cut holes for speakers and ports, painted black and covered with leftover RatShack grille cloth (my traditional hot glue application). The carved wood pieces come from a hardwood specialty store - you can find them online as well - and are pretty common in higher end cabinet construction. They are pricey, but keeps me from having to become a sculptor (hell, I struggle with a straight cut on the table saw). Stain, seal then glue carved stuff - regular old titebond then lie face down on towel with consistent weight on the board to keep it flat - it adheres to hardboard through grille cloth. Use Velcro on baffle and hardboard.

Using this technique - if we tire of the design, just get some more hardboard and make more. Geez - how about a shamrock design for march, Easter egg for April, heart for February, etc. How ignorant can one get? (Don't ask that of my wife - she'll have thirty minutes of answers about her extraordinarily good looking husband ;-)