Best products for baffle material s ?

@Ptss- Some points about Corian; it can worked exactly as
wood(routed/dadoed/sawn/dove-tailed), but should be worked
somewhat slowly. Drills and taps nicely, for mounting drivers
with machine screws and/or clamps(obviating the need for T-
nuts). Dupont makes colored acrylic epoxies, specifically for
Corian, that can be used to layer sheets to whatever thickness
you desire, or to make visually seamless joints in a cabinet.
Unlike wood; it can also be thermoformed, if(for example) you
want to create a curved baffleboard. Versatile stuff!
(http://www.homedepot.com/c/BP_Corian)

Thanks Rodman, very interesting about Corian. I like the idea of a curved baffleboard -but-Peter of PBN mentioned the crossover is designed around the precise dimensions of the baffle and I wonder if that means it should also remain flat and square? It's very good to hear it can be built up.

As long as the internal volume and acoustic centers of the drivers remain consistent with the original design; no negatives should arise. Only reduced diffraction, from the baffle. That's hoping that the system was not voiced to compensate for cabinet resonances. To me; anything the the cabinet adds is editorialization and colorization. I don'r want my cabinets adding anything, of their own, to my music. Of course: many appreciate those additions. Diff'rent strokes, etc.

Corian, Aluminium, carbon fiber all see use in high end speakers. My Magico S5's use some kind of composite material. I should enquire and ask what it is.

Rodman,

The width and length of the baffle is an integral part of designing a crossover for a speaker. I'd make sure that especially the tweeter sees exactly the same boundaries as in the original design, if the same x-over is to be reused.

I'd agree that rounding over the edges on the front baffle probably will have minimal effect. However don't go making a 7 inch wide baffle 12 inches wide.

Best of luck

Peter