Ok i promised pics of my box, not like most of you care but heres to anyone who wanted to see the box i built. I didnt have any silicone caulk so i didn't get to finish it last night but my amp gets in tomorrow so hopefully the box will be done and ready to go when the amp gets here.
As i was sanding this beast down there were some sweet spots that really made the box start resonating to the sound of the sander and it was glorious.
I hope you can get you subs to actually seal in them holes! It might be worth your while to cut another face plate board and use a router to cut the hole! Take a strip of 1"x 12" metal and make a circle cutter.
lol jesus i know the circles arent perfect i dont need you all to tell me that. I cut the first one out and used it as a template to cut the second one. the subs do seal completely and thanks for the advice but I dont have a router I had to make do with what I had.
Good job for the effort, and like stated there are relatively easy wasys of cutting perfect circles. Personally I don't mind the large compass and jigsaw method. I have one that extends out to 24" or so. $10 at the Depot.
If you make a living building boxes or are just tired of freehanding it a router jig works well and can be made easily as well as Mesodumm suggested.
Hey Big Harv your box is looking good espeacialy after you route the corners then it will look killer but please Man!!! Please!! just cut new front boards! Your sub has to seal perfectly if not you will have blow by which sounds like crap and wood putty will not do it, you need to understand how much pressure a sub can create. Here is a listing for a router it is a really good deal it looks like it has the guide for circle with it but I couldnt tell for sure, then you just need 2 bits a 1/4 straight and a round over and your set!! Or there is always Garage sales I have found many tools for way cheap. log on to your local paper and look for garage sales with tools! I found jigsaw, router, router bits, and nailer once for really good deal, so you can find really good deals!! Make us Proud!! redo those front boards!! You will feels better about your box for doing it!!!http://cgi.ebay.com/2HP-1-2-or-1-4-ELECTRIC-PLUNGE-ROUTER-UL-listed-1600W_W0QQitemZ180136537815QQihZ008QQcategoryZ20781QQrdZ1QQcmdZViewItem you can see by the circles I put in the box why we are concerned I have never seen a sub shaped like your holes, We are all just trying to help so don't get mad!! I don't want to see this go into a fry like pool boy got! I don't know what his name is now, I think he changed it! a couple of times! okay!! and defenently more screws 1 per 5" no less, I do 1 per 3" but thats me! With lots of glue! wipe off extra! Your doing good Big Harv keep it going! Thanks