Today's last minute progress.
Patched up the roundovers with bondo. The next time I do a constrained layer baffle I think I will make the top layer MDF because it rounds over so much better than plywood.
The good thing is that working under the sun makes the bondo and Duratex dry super fast which is good because I had to paint, sand, bondo, sand, paint, sand, bondo and repeat. Sun, FTW.
Wrapped the ports with Protecto Wrap to add some damping to the rather thin 2.5" ABS flared ports from PE. Protecto Wrap is good and dirt cheap and it works: http://tinyurl.com/p8z5k8u
I had a mini panic attack when I tried to push these ports in by hand......ended up using a hammer and beating them into submission. Got Gorilla glue all over my hands in the process....yay.
Ready for drivers.
Drivers installed and then I notice a major cosmetic flaw. The drivers are not centered perfectly!!!
I have no clue what happened but BOTH cabinets have the same error so at least I have symmetry.
Anyway, they are done for the show and the finish, while not perfect, is better than naked for sure. Shout out to Duratex for making life easy.
Inside for a quick test and all appears to be good. I listened to two songs.....next time these puppies will sing will be in Fort Wayne.