I'm taking a wait and see approach as far as EMI goes. If it proves to be a problem then I'll have plenty of motivation to do something about it
I'll do my best to make it easy to line the inside after the fact.
I hadn't thought much about the case acting as an amplifier, but that's going to be true of any case, isn't it? I've tried to keep the front of the box as free from holes as possible. The front will be a double thickness of 3/4 ply, with the frontmost piece hopefully being something more like MDF for looks if I can get a hold of some. The only holes are for the dvd, which will still be behind the front layer of wood, and the power/reset/leds. I've thought about putting baffles inside the side intakes. I'm not sure if lining the inside with foam to help cut down reflection will help at all.
Had a little bit of time to work on it today, but still didn't get too far. Rabbets done in the top and bottom pieces, and started on the side pieces for the bottom box. I'll snap a pic or two when I have something that starts to look like a box.