DIY mid to low end speakers. Worth the price?

You can also hit GR Research. They are very well respected and have Kitz available. In some cases you can buy flat packs of MDF… But in this case, you would only be interested in the drivers and the crossover. They do expect you to assemble the crossover… But I think they also have somebody who will do it for you if you like.

Thanks. I have looked at GR and will consider them as well.

One thing that had not occurred to me (until someone mentioned it in a video) was that hardwood expands and contracts over time. You take this into account with tables and larger pieces. If the front of the speaker is a single or even a couple of pieces of oak glued together it will move along the width of the board and this would put tension on the drivers that are mounted in it. So if I’m going to do this I’d have to figure out something other than hardwood boards to make the face of the speaker. Glued up narrow strips would probably be more stable and is not hard to do but might look strange.

It sounds like a good project and I suspect it will improve on your aged Polks. As a woodworker myself, I understand the tendency to want to use solid hardwoods for simplicity, no veneers, aesthetics and personal satisfaction. However I would recommend you consider a good veneered plywood instead, much more stable, and will dampen vibrations better than the hardwood.

I have built several kits over the years but never built cabinets from scratch.  I would share the following thoughts:

--Typically with well designed speakers, your $600 investment ought to get you speakers that compete with finished speakers at several times that price. Often the quality of the drivers and crossover components is far higher.

--I would not worry about doing all the testing noted above.  A well designed system with cabinet plans has already done that for you.

--I have enjoyed woodworking for years, BUT I would think very carefully about using a fully hardwood cabinet.  I would wonder about stability issues, joint integrity over time. Not to worried about damaging the drivers however.  I would suggest you consider a hybrid approach.  What about a mdf flat back that you attach solid hardwood side panels?  Could look very sharp and would be solid as a rock.

Go for it and good luck!

I'm a life-long woodworker and have built the GRR Super V's, so I wouldn't want to discourage you from building a set.  CSS has a good rep and, from what I've heard, yields a well designed product.  

While you could use solid hardwood for the side of the cabinets (the width of all four box-surfaces will expand at the same rate)..it wouldn't be advisable to use solid wood for the front and back of the cabs as the expansion will tend to break your box side joints. Gluing up multiple strips of hardwood won't matter, they still expand like a one-board panel. 

As far as sound goes..you'd be better off with MDF as it'll be less resonant. 

All that said..I've recently seen a used pair of Vandersteen 2Ce speakers in excellent condition for sale at $800.  If I were to think of a $650 project (for the hardware..the veneered ply or MDF is $80-$100 a 4x8x3/4 sheet)..I'd pop for the Vandy's and build something else. Try a cabinet with louvered doors..that'll expand your horizon's..speaking from experience.