best sealant??

I used wood glue to make it stick, then nailed it to hold it, then caulked the inside cracks. Also the edges of my box are all groved so it is air tight.

 
I use wood glue and screws to make the intial bond then apply RTV silicon to the interior edges... There have been debates on whether liquid nails is safe to use because of how the fumes might/could react with the materials used for the cones of the subwoofers so until I get a definite yes or no answer to that one, I stay away from it.

Using groves and dovetailing where the sides of the box meet could help with strength but unless you are planning to hurl the thing down a (few) flights of stairs, glue and screws should be sufficient. I prefer countersunk drywall screws over nails but that is more a personal preference.

 
I've gotta support the liquid nails on this one. I've been building boxes for quite a while now, and I've never had a single problem with it.

As far as the fumes are concerned, let the box air out a few days before you use it. This is especially important for ported or vented boxes because i don't know anyone who wants their entire car to smell like half-dried liquid nails (kind of a mixture of sour milk, vinegar and ***). If you don't let it cure and air out, i promise it will.

 
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