You know thinking back when I made the baffle board there used to be two nice hardwood dealers here but both are gone . I went to Home depot and wanted birch for the baffle , I didn;t need an entire sheet and they have 24" x 24" sections but very single one was warped even the 3/4" so iwent to a place called anawalt and looked throught thier precut birch and found the same warped section , then I went over to the rack that had cutoffs and found a section if either pine or fir plywood that had one side sanded and the other side had one knot . it was a bit thicker than 1/2" yet I figured since it was under shelter but still outdoors it was as straight as an arrow . Then I used what I saw in some baffle builds whcih I had 1/4" thick fiber board which I cut and used to hold the grill cloth away from the baffle. I perhaps should have used some of the 1/4" thick birch ply I had for that part but I never thought .
I was going to take the entire partical board baffle out of the pine cab but I saw they were stapled in , I was going to remove the partical board from the routed groves in the pine cab and make pine stays and glue them in . Then I cut the partical board baffle out using a good jig saw and used the edge of the jig saw to determine how much of the partical board baffle was left , it was a bit wider than I wanted but the speaker could fit in between and I also thought well if I leave the bottom part of the partical baffle in place it will keep the old pine cab square .
Perhaps one day If I live that long I will take out the rest of the old partical board glued and stapled in baffle and make pine stays to fit the routing and get 1/2" thick baltic birch ply for the baffle.
It has been over two years since I replaced the baffle and it is still as firm and true as it was , the old partical board was not really brittle and didn't chip when i cut it , I just never cared for partical board for anything. The weber sig 12s alnico is not heavy . I stapled the grill cloth into the edge of the plywood baffle then cut it so it was not between the baffle and the cab partical board side stays . I see it done this way most of the time. I don't know if having the grill cloth between the stays and baffle would matter . I would have prefered to staple it on the back flat side of the baffle rather than on the edge , so far it has stayed put .
What ever , it is what it is now and seems ok so far. If I recall and memory fades I think I sealed the baffle with shellac before air brushing it flat black.
Time flies , I used to get all my wood to make my strats out of alder and flamed maple and a nice rosewood slab for the fingerboard for $40 not it costs over $80 just for the alder to make one body and the alder is not even from the same plank .