Aha! Thanks for another wake up call Steve! I wouldn't make any progress without you!
You're intuition must be itchy cuz I'm actually already working on it today. I'm regluing the T nuts with CA glue because the PL construction adhesive that I used before is very strong and tough, but it doesn't wick under the TNuts to make a good enough joint. It's more like taping them on from above. I could only glue one side of the TNuts with PL while the drivers screwed down to hold the nuts in place, so some of the TNuts could rock a little on the other, loose side. The CA seeps under and glues it tight. I'm using Bob Smith medium viscosity 15 second cure, but on the rough side of the masonite it cures very slowly, but it's solid after 10 minutes. Luckily I haven't glued any fingers together yet, but there's still one baffle left. I like the first wiff of CA, reminds me of happy days in my previous stress free hobby of model airplane building. But after a few minutes the smell gets old fast.
Also today I will drill 4 small holes in each of the 64 divider panels that go between each driver, holes to allow the hookup wires to pass through. Some of the panels need less holes, according to the wiring schematic, but the most holes any panel needs is 4, so I'm drilling 4 in all of them, then I'll fill the unused holes after the hookup is done. That's easier than gluing each divider panel in a "correct" position, and messing it up. Also allows changing the wiring schematic if I already messed that up but don't know it yet.
Since all the drivers move the same, in same volume chambers, there shouldn't be any air movement through the holes, but I'll seal them up anyway, and the wires through the holes. Once the holes are drilled I can start the sexy job of gluing up the boxes.
Edit: My wife wants me to finish these so she can hear what all this work is for. So I am motivated to show it off for my biggest fan and that should accelerate my progress. Just don't hold your breath!