I purchased the 1/16” lexan poly-carbonate with dimensions of 16” x 60” for $32. Routed a 1/4” groove for the lexan to sit in, top and bottom. Cut all the support pieces and slapped it all together for a dry fit run. Here is the result:
So far… it does not look like I’ll win a beauty contest with it, but it will fit my utilitarian funtion. I made alot of mistakes and errors which have given me much needed experience in working on MDF, using Microfence jig, first time really using my bosch 1617 router, etc.
Next will be cutting a 13” diameter thru the top of the baffle for the 7” bellmouth outlet, assembling inlet 6” (well, actually 8” x 4.5”) port, and doing a function test. Who knows, might not have to silicone or caulk or whatever to seal up the chamber as everything was a good tight fit.
And notice.. the baffle cut out arc has been changed from my previous error: the opening now starts much later and the end stops right before the inlet.