In the first post you conceded that the current enclosure is likely not designed for the driver, and that you are aware without the exact specs your box may not be an improvement. You'd be satisfied with a lateral step if you achieved smaller and lighter.
I'm going to remind you of a concept you have to have heard sometime before. K.I.S
S.
I think you are getting lost in minutiae. Assorted flared ports are available from many sources online. I don't think this box really requires them, but your choice. Plenty of perfectly fine straight ports are available too.
The idea bogey suggested for a 3.xx cuft box with 6 ports that can be plugged or unplugged to suit is a plan I'd run with for this project.
Standard grade half inch or 5/8 ply and a decent bracing scheme. Maybe go 3/4"for the baffle. Butt joints and overnight clamps with PL. Set back the baffle 3/4" from the front of the cab. Line the bottom, back, and one side with some batting. Rubber feet on bottom, and for grill standoff. Fender washers and some kind of rigid mesh for a grill. Add connectors and a handle. Play.