Above: Whatever imperfections were spawned while fiddling with the port were easily eliminated with the belt sander and a nice file.

Construction is simple, though. If you take a look at my schematics you'll see a set of instructions I wrote to myself on the subject. (Of course, they are directly based on Wayne's orders.) The Vent is attached at two locations - the rear baffle and the interior brace. Both should have a circle cut into them as depicted, which you will notice are smaller than the interior diameter of the PVC itself. Once these holes were cut we again broke out the 3/8" rabbet bit and routed along the appropriate sides of said pieces. Since our PVC was not exactly square, the next step was a bit more complicated than it should have been. We decided that it would be a good idea to use the polyurethane glue in this situation so that it would expand to fill any voids and assist in keeping the enclosure air-tight. Polyurethane glue is a pathetic filler, though. Don't toss out the wood putty (or silicon caulk)! Having a perfectly airtight cabinet (except for the vent, of course), is of utmost importance. We had to be extra careful, though, when attaching the PVC to the MDF to be sure that both the internal brace and rear baffle were perfectly parallel. Of course we screwed up one of them and ended up gluing and squaring again. D'Oh!