Got new rear panels built tonight (3/4" Birch Plywood from my favorite lumber store in Houston: Stahlman Lumber), and I didn't have the heart not to at least use 2 coats of Duratex on the bottom of the boxes where there was actually some bare wood.
Between that and 2 coats on the front, back and sides of the new panels, I went through about a pint (one little plastic bag) of Duratex. I applied it with a brush despite the instructions, going for kind of a "linen finish" which works nicely with the "weathered" look of the speakers.
New adhesive stencils will be ready tomorrow. I sent a local sign place a PDF at actual size (downloaded from Klipsch) and they're generating them for $5 a pop. (I tried some reproduction badges but basically they clash with the rest of the project since they look new and everything else looks old.)
I'm treating the boxes to brand-new Penn Elcom jumbo rubber feet, and all-new marine-grade screws.
In the end they will still look well-loved (that's my style), but mechanically and electronically they'll be better than new (also my style).
rs