Re: How to attach the baffle to the cab?
I think this is a key question. I looked inside my Pathfinder 15R and this is the way they seem to have done it.
Measurements have to be right on even after the grill cloth is affixed. Some supports run vertically and horizontal inside the cab, the exact depth of the baffle wood. I don't see how those are attached but maybe glue. I would probably glue and then screw.
Next the baffle board was probably placed face down on a table and the housing lowered over it so that the vertical and horizontal supports fit perfectly onto the baffle board.
Next the baffle board is attached to the supports by screws through the back of the cabinet housing. I am not skilled at this sort of thing and it seems like the small size of the supports would make it impossible to get a drill inside the cabinet, but maybe the length of the drill bit is way longer than the depth of the cabinet.
Hopefully someone will come along before too long and set us straight. I really want to do this as well, and so far have put it off due to not knowing exactly how. .