Seeing that it is a little slow around here... I thought I'd verify a couple of design questions with you. For reference, I've decided to build a AV15 based subwoofer (already on pre-order) powered by a JBL MPC200 amp in mono. I do a lot of music listening, so I decided on a 6ft3 enclosure ported to around 21Hz. Dimensions: Does anyone have the exact dimensions of the driver for the cut out? As well as the actual volume of it (to add to my internal volume)? Grille: I would like to fabricate a grille to cover my driver.... yes I know some are thinking "show it off" but you have to admit big round shiny things have limited WAF. How far would the tissue have to be from the mounting flange to avoid contact with the driver? I figured it should be about an inch from the surface the driver will be mounted on. Correct me if I'm wrong, but the logic behind this is; in it's fully extended position the woofer surround is fully stretched and the edge cone is what will touch the fabric, the AV15 has a 23mm Xmax , the cone edge sits about even with the back of the mounting flange in its resting position. Am I safe? Box construction: I had originally considered going sonotube, but seeing the time I have before getting the components, I think a box would look nice. My intention is to match my old Birch Plywood Klipsch.... but my question here is that I often see the two most "accepted" construction materials being MDF and void free marine plywood. Obviously the box's resonant frequency would be quite different in plywood vs MDF but will it hurt the sound? I have access to 5'x5' x ¾" sheets of the birch marine plywood and it would be a relatively close match to my mains. Is it better doubling the box with MDF, or just KISS? Ports: to flare or not flare? I'd like a single 6" port... which I don't have access to flares for, but will my velocity be low enough not to hear port noise? Thanks ahead for any help... Rob.