This is the "deluxe stile" with finger-joints.
Glueing with Tidebond gives best results in already an hour.
A perfect connection.
Roofing ceremony!
These cleats will fix the baffle.
That a damned dirty job!
This is a smooth curvature!
6mm plywood is fine.
Here cutted for a 10" Speaker.

Making the cabinet

Pic 1: The ready-cut boards get their finger-joints milled, which garantee a perfect connection.

Pic 2: The joints are glued and pressed firmly together.

Pic 3: This is what a raw finger-joint looks like.

Pic 4: The cabinet has been glued all around.

Pic 5: The cleats that will fix the baffle are glued.

Pic 6: Now the outer angles are milled to a smooth round. I suggest to make this outside, because this may rescue your marriage.

Bild7: The result is a perfectly smooth curvature at the outer angles all around.

Pic 8: Now the boards for the backside are cutted.

Pic 9: The speaker hole is being cut and flat cleats (5 x20 or 30) that will give the grill fabric some distance from the baffle are glued.

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(c) 2010 Dipl.-Ing. B. Brieskorn