well, material is up to you, I use MDF because it is smoother final product and takes screws better.

The terminal cups, I insert them in either end, depending on which way I insert the woofer, so the terminal is on the correct side of the woofer.(the one with the binding posts.)

i put my terminal cups on the back, as high as i could, because i wanted to be able to take the top off easily, not having to worry about wires.  make sure you put the insert before the terminals as it may not fit.
i used particle board on both my dbs because i ordered pre'finished and pre'cut panels.
it seems to me that all the plans on the site are very detailed.

The problem is that not all the dimensions are on every board, so it requires a little math to work out every dimension.

It can be harder for people who are not visual thinkers, where as some people can just picture how everything goes together.

LOL Bob, we don't think you are a dickhead, just some people can look at plans and be all like, alright build time, whereas others are like, Where does that come from.

I am used to seeing plans as cut out plans on a piece of mdf, but 3D plans and stuff not laid out in a cutting diagram take me some time.

well been practising cutting circles that was another issue i had to resolve first I  got an old router from my dad and built my own circle cutting jig this morning been practising on anything that would stand still long enough for me to cut a hole in it    really surprized my self with how accurate i have been able  to set the hole sizes

so now i really have a question about the drawing    on page 2 it shows the speaker sitting down in a little bit of a machined out relief  how critical is that detail  and i guess the thru hole needs to be just slightly bigger than the suround so it does not hit or rub  i can see that by doubling up the baffle board here this makes for a really solid speaker mtd

told you guys i was new at this  but i am willing to learn  did i mention that i hate wood   i am much happier if i can weld it grind it  etc

this is my other passion  go here
http://frost.bbboy.net/vwengineconversions-viewthread?forum=14&thread=3

regards 2088bob

i remeber the detailed cutout on the actuall baffle. that is just to center the speaker. with a bit of help, you can mount the speaker without that detail. i say it's not worth the extra stress to actually do that cutout.
you need to measure the inner diameter of the gasket :

that is your speaker hole diameter
sorry for the nasty pic.
don't cut the speaker hole to the size the manufacturer says unless you want to mount it to fire in the sealed chamber