I want to recycle a pair of stout 3/4" plywood cabinets that measure roughly 29"h x 18"w x 14"d. I plan to make a new baffle board by gluing 3/4" plywood to 3/4" MDF, then using a plunge router and circle jig. I calculate the internal volume at ~2.9 cu ft minus some bracing, so about 2.7 cu ft. I penciled a layout with the 15" up from the bottom 3", and the bottom of the horn flange less than 1" from woofer edge. This appears to leave plenty of room for a horiz. brace inside between drivers, and also leaves room for two 3" circular ports (one in each bottom corner).

Questions:

Any tips for gluing two pieces about 27 x 17"?

Is internal volume pretty close to the Four Pi?

Layout is different from Four Pi pictures, with horn smack over the woofer, and ports in bottom corners. Any issues there?

Thanks,
Rick aka tubino