Bulletproof Glass Enclosure?!?!

BondingPolycarbonate can be mechanically bonded by standard methods. It can also be cemented by using a solvent such as methylene chloride or adhesives such as epoxy, urethane and silicone. Polycarbonate and also be ultrasonically or vibrationally welded.

Check this out too:http://www.loctite.com/int_henkel/loctite_us/index.cfm?pageid=325&layout=2

As for mountiong the sub, a polished aluminum ring, same diameter as the speaker of course, about a 1/4 inch thick with holes threaded would be real nice. The ring would spread the load around the entire speaker. I wish I had a bunch of the 1" poly myself, now that I think about it. Good luck:crazy:

With the right stuff and know-how the seams of the box could be pretty dam much invisible. It would be one hell of a project though. I would practice on some small scrap peices first, because I'm sure it will take a few swings before you hit a homer.
Mechanical bonds, yes. PV was talking about the chemical bond you get between wood and wood glue. Chemical bonds are usually stronger than mechanical bonds. It's like comparing liquid nails on MDF to wood glue.

 
Found it. It was an acrylic enclosure, not polycarbonate. Made by velodyne:

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