Updated progress pics, can be found on my SD webpage, page #5.
Baffle template made from posterboard:
Baffle cut from 3/4" mdf:
Used a roundover bit on my router to curve the edges:
Test fitting on door panel. You'll notice that the top edge has a gap that needs to be filled in, this is where the ABS plastic comes into play. The 3/4" at first I thought to be too thicke and would protrude too much out of the door panel, but in the last pic you will notice that the baffle really doesnt stick out more than the stock grille did. However, I think I may make a second set out of either 1/2" or 5/8" mdf to compare the thickness to: Enjoy!
