After much labor and time I can say that my home theater (version 1.1) is now complete.  

The bad news is it took me two years of working on it off and on to finish.  The good news is it's done and I learned quite a bit along the way.  The first thing I noticed is how much I have to learn about building speakers.  Every time I begin to get a handle on one aspect of it I find there's a whole new dimension that I haven't even scratched yet.  As such it makes for the perfect hobby, there's always new designs to try, new construction techniques to apply and new drivers to test and new crossovers to wire up.  With so many things to tweak I'm sure home theater (version 1.2) coming along any day now.

I'll try to convey some of the things I found out about speaker building and maybe even finish carpentry so that you might avoid some of the same pitfalls if you choose to begin a similar project.  I hope you find something useful to take away from here.

Best regards,

Jim