Read Martin Collom's "high performance loudspeakers", Vance Dickason's Cookbook of Loudspeaker design, and the two books by David B. Weems, those will all help. You can build it out of concrete, MDF, soapstone, marble, corian, special honeycomb structured aluminum composites, special plastics, etc. The deader stiffer stronger the material the better. They are all good, but beyond MDF they can be expensive and difficult to work with, albeit better.
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