I know a lot of people enjoy build logs so here ya go. So far I've cut everything and painted the port. I also rounded the port edges. It's gonna be around 3-3.4 cu ft NET, I don't remember the exact number, and it's tuned to around 24-25 hz. It has 25 sq in of port area which is more than TC recommends.
The front baffle is double thick and everything else is 3/4" MDF.
Pieces all together, paint cans that I used. Got them from Lowes for 3.12 a piece IIRC.
The speaker cutout was made with a jigsaw. It's about the 4th speaker hole I've made with a jigaw and I'm becoming exceedingly efficient at it (sorry I just watched The Matrix Reloaded ) seriously though I am much better now than when I made my first hole.
Close up of one port wall. Used 1/2" bit on my router to make the curve. I also used some wood filler on the edges of the MDF then sanded to make smooth and ready to paint. I also sanded the MDF of course. 320 grit I believe.
I'm gonna glue it now, and I'm gonna use the least amount of screws possible, hopefully none at all, but I only have 2 long and 2 shorter clamps so screws might be required.