Hi Gerald,
Boy, you are taking your time arent you?

Stuffing:
We used to suggest polyester fiberfil (Dacron pillow stuffing), as it was cheap. However, you can use an open cell foam instead. Assuming that you opt for the foam, use the 2" stuff. Placement should be a single piece that covers the bottom panel of the cabinet, another for the back and sides behind the woofer, and another for the top panel of the cabinet.
Port:
Make the port length 3.5"
1" Radius:
It's doubtful that you'll do significant harm. You will change the dispersion characteristics, but that may turn out to be a good thing. I assume that you intend to use a thicker baffle to accomodate the radius. It's not needed except to accomodate the 1" radius.
Best regards,