Still baffling

To fix the destructive interference issue, I building a new baffle. It will also be almost twice as thick, partly to reduce resonance, and partly as a way of loosing all the ugly screws on the front but still allowing access to the inside. The star of the piece is the new circle cutting jig.

(It fits only some Craftsman routers - the plunge router has a larger base, but it does fit the fixed base model). Depending on which way you put in the center locating pin slider thing, you can cute really small circles (<2 inches in diameter) to fairly large ones.

The router jig enabled me to rebate the drivers which I hadn't done on the first baffle. Although I don't understand the physics, there is a strong school of thought that the tweeter in particular needs to be flush with the baffle.  Presumably something to do with diffraction from the sharp edges?

This shows the double layers and the neat rebate the router cuts. The lower section of the baffle will be screwed in close intervals to the cabinet, and the upper section will be attached to the lower plate with the driver mounting  bolts and possibly four screw, one at each corner. 

The AC 250F1's are now in so I want to get this (Phase IV) completed before building he new cabinets.Once the new baffle is built I will likely line the cabinet with SAE-13 or SAE-15 1/4" felt. I didn't do this first time round since I wasn't sure I wanted to blow $80on felt if the sound really sucked. (I also wanted to test the reflective diffusing properties of the cabinet design without any absorbing material).