Gary Eneberg has made a great looking pair of speakers and documented the steps. For a total cost of $430 US it is a fantastic deal for such a nice piece of work.

"The enclosures were made using 3/4" Baltic Birch plywood except for the front baffle which consists of two pieces of 1/2" plywood laminated together. The inner piece of the front baffle fits tightly into the cabinet opening. The outer piece of the baffle was cut larger than the outside dimension of the cabinet and flush trimmed to size once the baffle was glued to the remainder of the cabinet. The port is removable allowing for port adjustments later should they be required. The port was made removable by cutting a hole in the inside piece of the 1/2" plywood which was the outside diameter of the PVC port. Once the two baffle pieces were glued together, the outside baffle hole was cut with a flush trim bit riding the inside of the port. "