Best products for baffle material s ?

Rodman,

The width and length of the baffle is an integral part of designing a crossover for a speaker. I'd make sure that especially the tweeter sees exactly the same boundaries as in the original design, if the same x-over is to be reused.

I'd agree that rounding over the edges on the front baffle probably will have minimal effect. However don't go making a 7 inch wide baffle 12 inches wide.

Best of luck

Peter

Of course, Peter. Somehow- I thought you had already covered
that elsewhere and that the OP had replied, in the
affirmative.

BTW, Ptss: You mentioned doing the cabinets in black.
Corian has a color called, "Nocturne" that can be
polished to resemble a Piano Black finish. Would look
sharp, with no visible seams and a 1/2" radius, on all the
corners. Personally; I'd dovetail the sides, top and bottom
and install the front and back with dado joints. Talk
about a solid/non resonant cabinet! I can send you a sample
piece, if you want to get an idea of how rigid, dense and
workable it is.

The width of baflle influences more the frequency response of the driver, or its spread?

Magico got back to me and clarified the material used in the front baffle of the S5's is pure 6061 T6 aluminum which is not extruded. Interesting as the finish doesn't feel like aluminium. But today I gave it the knock test & it sure does sound like it! I'd estimate the front baffle is the same, or similar thickness to the 1/2 inch thick side panels (ie: bloody solid).