yeah, sanded birch is the way to go for the baffles. I believe its 12 ply or so, and very sturdy. I've been a carpenter for 30+ years, so the woodwork comes quite easy for me. Layout, cut and Fab the birch box in under an hour. Sealed with polyurethane caulk, and screwed pretty heavy with 1 5/8" coarse thread drywall screws. Tonight I will sand the whole thing and make her pretty, and smooth.
Each box volume will be .62 cu ft with sub installed. SI recommends .5 to .7
The first thing I did was level the bottom of the hatch area, by gluing down 2 pieces of 5/8" MDf on each side, and filling in the low areas with some 3/4" firing so I had a nice, flat work area that was easy to attach my boxes to without screwing into the sheet metal.
I used a very high quality Polyurethane construction sealant for that, and I will lay a 1/8" sheet of weatherstrip foam between the boxes, and the floor layer, just to combat vibrations. Probably not necessary, but it certainly cant hurt.
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P99rs Head Unit--- Amps- 2 Pioneer Prs800d --- Zapco ST1000MX---Zapco ST-4XSQ---- SI BM mk5 Subs---SI TM65v2 Midbass--- SI M3 mids--- SI M25 xbl2 tweeters ----- 2016 MECA street class 3rd place at world finals
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