Dave was kind enough to email me with the following info, hopefully it's ok with him that I share here?
"These dimensions will give you the same internal volume as the original Auratones.
External Front: 6 7/8" x 6 7/8"
External Depth: 5 7/8"
Inside, all the corners are glued and pinned with 3/4" square softwood/pine and the back is flush fitted onto a square of this section too.
Outside, all the panels stop short of the corners and 1/2" quadrant is used to make round corners. All the panels are made of 1/2" chipboard or particle board. I didn't bother mitreing the quadrant, I just filed and sanded one end round after the glue had set.
Construction: Holes are drilled through the quadrant for panel pins which are recessed and back filled. All the joints are also glued with PVA. The back panel sits on a thin foam speaker sealing gasket to make it airtight. There is also a small wad of bonded acetate fibre inside to soak up the sound from the back of the speaker.
I managed to get a speaker with a similar response to the original, see my posts in DIY, but the volume and shape of the box has a great deal of influence on the sound, only the top end is governed purely by the speaker. The speakers are screwed from the front and sealed carefully with silicone mastic. (cover the cones with something tough when screwing near speakers)!!!
I primed it in white, rubbed it down gently then painted it in pale yellow emulsion paint, then gave it a coat of brown varnish for the antique effect.
I copied the logo off the internet and reduced it in size an printed it off on a colour laser printer and stuck it on with the varnish.
Thats about it, good luck! "
all the best
Dave
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