Question for all you constant builders....

3/4" MDF is the most common. Birch is occasionally used, but that costs more $$$. For most purposes (like a pair of 12"s), no more than 3/4" is really needed. If you're going to do a wall with two 18"s, you're going to want considerably more stabilization in the form of thicker walls and metal rods holding it all together.

 
Being one of the people who have used birch and mdf as well as several other types of wood through out my years of building boxes... I can say that birch makes no less dust then the others... its just not as fine... Still a pain in the ***... less forgiving if you drop it and harder to work with.... i would not recomend you use birch unless your going for the natural wood finish... I would go with trupan over normal mdf though... The weight now days will cost at the pump... my Birch box that i just finished weighs a ton still... i just wanted a natural wood finish for part of it...

 
MDF in 3/4" thickness is the reference standard, everything else is a derivation (not in the literal sense) of it. That isn't to say that MDF is the best, because it isn't, but it has the highest ratio of advantages/dollar.

And yes, I've basically tried them all (mdf, hdf (in .5, .75 and 1" for both), two grades of PB, birch ply, oak ply, baltic birch, and OSB), minus TruPan.

 
The nice thing about larger dust particles is they settle out quicker and don't end up covering your workspace in a superfine layer of basically talcum powder that you will never fully clean up.

Birch ply is much more tolerant of being dropped. I can look at a cut piece of MDF and the corner will flake off. There's a reason it comes with 1" of extra in each direction: to keep the usable piece full size when the edges get effed up.

 
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