Ah - finally a subject I know something about.
I looked at the pix. They're certainly gorgeous looking boxes but I have a number of reservations about method and materials/. I presume you're well committed to what you've already done, so don't change that for Gordz sake but if you don't mind me airing my thoughts.. Basically if I were to build another pair for myself, these would be some of the consideration
Firstly, I'm not convinced about the notion of full range drivers, Impossible to move a sufficient air mass with a small cross-section, impossible to get responsive high frequency with a large cross section, basically. There are ways round this but they are compromises, of course, and always introduce non linearity, That may not be unpleasant and may well be a preferred choice if you like excitement more than pedantic accuracy - e.g. disco-ey rock rather than choral works... However.. I've not seen any frequency specs on the site, so assume that the 42 Hz is a
3dB cut off but have NO idea of the graph shape which I'll also assume to be very lumpy
They are quite light for their size, This would be a problem with an enclosed box or a reflex design, but these are horn-loaded, and so the _acoustic_ impedence is extremely low (nothing to do with electrical impedence, O.K.?) Not much energy is stored in the mechanics of the system,. It doesn't build up enough "breath holding" to suffer as much from panel resonance as more traditional designe. Nevertheless, I would still avoid natural wood for the panels (first choice would be flooring type chipboard - NOT mdf or ply) with plenty of lateral cross bracing which would kill any panel resonance without adding too much mass. I'd use ply for sound-reinforcement/public address speakers because of its durability.
Flush trim..
I know you''re all excited about having done a nice job of it... leave it that way. It'll be fine.
but If I were doing it all again I'd go for round-over of the largest radius I could fit. Sharp edges introduce diffraction. I can hear it quite clearly on mine if I move around much. It's not as bad as it could be as the baffle boards are carpeted and set into hardwood edging and the main surfaces are fabric covered, not veneered. They sound absolutely fabulous, but IF I ever move to a bigger house again I'll recut the baffle boards in block laminate "butcher block" round the edges over and veneer the sides. That way the sound can't get "snagged" on any corners (yeah I know, and I know what **** is going to say, but it's a reasonable analogy :-) ) The surround port hole on the website designs gives me cause for concern because of its intrusive profile (yes, I know it's rounded but I think we need to minimize the necessary evils of having to have an enclosing box rather than bolt on something cosmetic which will likely introduce new problems.)
I like horns. I prefer front-loaded designs for their attack, but all horns are very very "fast" if a little "shouty" I have a nice pair of altec lansing copies loaded with 300w celestions, and they are THE loudest things on the planet short of a space shuttle launch. Great for vocals and (ahem) percussion but they need separate bass rigs to bring the lower frequencies up to their level, and _that_ requires huge volume of cabinetry and about 3k of engine, so the compromise is generally to put up with the lack of kerboom rather than lug a shed-sized bass unit around. It does the job, but it's not "hi-fi" used like that.
Now I know that that's a LOT more extreme than the horns in your application, but to a small extent, the same compromises apply. I think you'll have a slightly lost bottom end and the midrange will be faintly like shouting through cupped hands. Don't misunderstand, I'm not saying they will sound bad. I AM saying they are unlikely to be frequency-flat. If you want flat, you need to go for transmission lines, not horns, and they eat power, need to be massive, rigid and they will dominate a room completely. TLs tend to impose their sound regardless of environment wheras other designs tend to "excite" the room and their sound will change dramatically depending where they are placed. The most dramatic example of this that I can think of is the KlipschHorn, which is another rear-loaded design but it uses the corner of the room it is in as the "inside" of the exit mouth of its horn. "I am your father, Luke!" rumble rumble rumble..watch all your windows fall out. Gorgeous things, but not really chamber music monitors.
Transmission lines.. Mine are (I think) 40 high, 13 wide and 18 deep and 110 lb each. I don't move them much. and I know someone who consider them "dull" - but that's from a guy with a Technics system that he plays with the loudness control on at all volumes.
I don't think your project will sound "dull" I think they are "objets d'art" rather than hi-fi components, though and that's not necessarily a bad thing. I am an ex hi-fi junkie. It was pretty obsessive, once upon a time but I'v calmed down a lot since going forCDs and er, MP3s. Now I listen to old time radio and don't care about the bandwidth.
Yeah, I'm waffling again but this is stuff I'm comfortable with, whereas I can't tell one end of a jointer from a jack. I'd have been rubbish in the war as a plane spotter.