*taking notes* one day... i will have a system like this... after i mess up... ill be calling you to help me cover my mistakes

 

You'll be fine measure 3 times / cut once

 

How do I cut the body filler? (fingers still sore from sanding w/ 36 grit!)

 

an air sander the whole process might take you 30minutes

 

& a really good respirator

 

and that's a really good point

 

how did you cut the inside lip on the round mdf cutout that the port tube and subwoofer rest on?

 

With a routing table, using a rabbet bit with a......3/4inch bearing on it.

 

cool, i also found this way to make the ring around the sub, I think i'll do it this way even though it won't look as nice cause its easier

http://web.njit.edu/~cas1383/mdf%20rings/

 

Actually the router is way easier than that....

With the router you make the ring size with a pen, router the outside, so now you have a circle. Drill a second hole on the inside and router that out. So now you have a ring. Then just switch bits to the rabbet and go around the inside and you done...

There's a little more than that to it but that's the jest of it.