-I read elsewhere that T-nuts don't grab into MDF very well and I have come across a number of comments from people that used ply for the 'outer' box for this very reason. Are you guys suggesting that this is unnecessary? ...or are you suggesting to drill right through the baffle and mount the T-nuts on the inside of the baffle?
I'm not sure you get how a T-nut works.
To answer your question... Yes, using plywood for the outter layer would be totally pointless if you use T-Nuts.
T-nuts are where you have a bolt that goes through the cabinet (doesn't make a diff what the cabinet's made out of 'cuz it's not really being held much by the cabient.
The actual 'T-nut' goes on the inside of the cabinet. It's simply a 'nut' that has a frame around it with some spikes that dig into the MDF or whatever you use so the nut can't move.
Some people do complain that the MDF can chip when you hammer the T-nuts into it but I've used a LOT of T-nuts in MDF and there's nothing to worry about. If anything you can add a little Liquid nails around the nut so make double sure it won't ever move.
Some people use plywood on the 'inside' layer 'cuz it will grip the T-nuts better but in this case you only need a REALLY thin layer of plywood and can be any cheap crap.
That's overboard IMO though. A waste of time and money for no benefit.
Hurricane nuts are very similar to T-nuts but the frame doesn't have any spikes to dig in, the nut section has the gripping part. Hard to explain though. Look at PArts Express if you want to see what they look like.
I never used 'em but you can see that they're a good idea. A clever reworking of the T-nut idea and great for MDF.
T-nuts are still cheaper though and work great so I'd jsut stick with those... but like I said... it's all overkill for most any speaker drivers. Certainly no need for all the trouble it'd take on a pair of Alphas.
I wouldn't worry about having to get the woofers out if you use screws. At most you'd have to do it one, maybe two times but probably not ever at all and the screws will hold fine through all that.
You can add a little wood glue or other tricks to make sure the screws hold if you have to take drivers out over and over again -but why would you right