Well, one of the enclosures is just about complete. I still need to add some mineral wool, attach the side, cover the screw holes in the baffle and do some sanding around the port opening. The baffle will be the only visible part after it's installed.
It's turned out pretty well so far, IMHO. The only real hiccup had to do with the driver. Don't know what kind of fasteners are meant to be used with this driver, but the smallest propel nuts I could find were 14"-20, which means 1/4"-20 bolts, which means the bolt holes in the driver were just a little bit too small.
So, I bored them out without any problems. But, the mounting flange isn't overly wide, so when the propel nuts were inserted into the holes I drilled into the baffle, the nut flanges overlapped the driver hole
, as you can see in the photo. The sides of the driver fouled on the nut flanges when I lowered it into the hole. This was also fixed fairly easily, by grinding off the nut flanges flush with the edge of the driver opening.
I had considered assembling both enclosures simultaneously, in an assembly line-type setup. This could save time with tool setup and so on. However, my shop isn't very big and that would make it very awkward to try, not to mention somewhat hazardous. Besides, if I screwed something up on one, I didn't want to repeat the same mistake on the other. So, I'm willing to take the hit in extra assembly time.
This thing is a bit heavy, so after I cut the holes in the ceiling think I'll attach a pulley to a roof rafter in order to pull it into the attic. After they are installed, I may add some external bracing, especially along the top, above the vent, which isn't really braced at all right now. I'll post more photos when they're both complete and ready for installation.
Any comments or suggestions are welcome! Unless, of course, you suggest I tear it apart and start over....