1. What wood should I order from my local lumberyard?
1/2" void free plywood, with lots of equal thickness plies. There are a few options there, but that is the key. There are threads on greenboy's forum discussing plywood options and availability. Baltic birch is common, some use arauco or okoume (ok, fixed spelling... surprised I got arauco right the first time).
I read somewhere about a "new" lightweight foam type material. Is this suggested or do most just go with wood?
Unless you're already handy with fiberglass, epoxies, foam boards, and so on... no. That's a pro job. If you want one of those, have Robby (Art of Noise Audio) build you one.
- fEARful 15/6 Deluxe Kit (without "flatpack" (wood))
Yep.
If you plan to build your own using the provided parts, no. If you'd rather it come already assembled and ready to install, yes.
- 100v or 250v Shunt Capacitator?
Up to you. I'd take the 250v, because I'm an overkill kinda guy. But the 100v is supposedly fine up to 1250W (from your amp). Which is quite a bit for a single 15/6.
Up to you. If you want a tweeter, choose one. For recommendations, go to greenboy's site.
- Jack Plate Choice - 2 x Speakon & 2 x 1/4"?
Pick what you like. I'd go with just Speakons... 1/4" jacks can be leak-prone.
- Handles - Right Angle or Deep D?
Do you like spring loaded handles like you'd find on an anvil style road case? Or big round inset handles? Take your pick.
They come with the kit.
- ? x screws (of different lengths)
In the kit.
Am I asking for too much hand holding?
Maybe a little, but no biggie.
Step one is to read all of the links on the front page at
http://greenboy.us. It's all there. And way better than trying to comb through megathreads.