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I had the advantage of having the side pieces cut on the CNC router at Audio Artistry which made the task a lot easier.  Still, Siegfried has provided all the details to be able to do this with with just a hand router. The baffle for the 10" XLS drivers is pretty straight forward.  This goes together really fast!  The upper baffle for the Seas drivers then just mounts directly on top of the lower baffle.  Again, very easy! I taped up the Cherry front and then painted the entire baffle before mounting the sides.  I also finished the Cherry sides using a clear lacquer called, "Dull Rub Effect" before mounting them.  The edge of the MDF sides was then painted with the high gloss lacquer. The sides are then attached with glue and screws.