Have you thought about 3D printing them? Once you create the design, you could even share the file with your customers so they could print their own. Even if people do not have access to a 3D printer, we could use something like www.shapeways.com. I am sure there are other sites that 3D print like this one. Having to buy the baffle could limit the creativity of the builder and adds a lot to the kit price and to the shipping cost.
This is clearly a business decision that Danny has made, both for his profitability from his design and also for Jay and Don who are making the flat packs. They need to make money from their hard work as well.
Plastic makes the most since in the long run IMO for the customer but limits Danny's control over the product that he designed. That ultimately costs him and the people he is working with money.
Just an opinion coming from a long time small business owner that understands what it takes to make a profit in this competitive market we live in. Taking care of the customer is the ultimate goal. At the same time you have to protect what you have spent your time developing and make a profit on it.
Edit: I see Danny has chimed in so I will defer to him why he is doing what he is doing. I think volume could also play into any decisions relating to moving forward simply from an economics stand point.
I'm pretty exited that this whole process is happening and while I'm very happy with my Super V's I look forward to Danny's new designs.