I was wondering about your stacking thoughts Scrub. I kept coming up with one main advantage of just spaced stacking - the second fan wont have to work as hard and would thus be quieter. Putting a filter in between would seem to make more sense in getting the most from both fans.
Something to remember is that the first fan is muffled/silenced by the carbon in a push/pull setup. My thoughts on stacking - I look at it like I look at active intakes - sure it may technically work occasionally but it's a black art. I would incorporate it into a design only after I'd exhausted (get it?) all other opportunities. I.E a better fan or a push/pull like mine.
Hey man I thought you said I had ages to do it? lol. No worries anyway, I haven't forgotten, I've just had issues with the new cab and making a new new one. All good. One thing though, I have a diy filter completely different design from commercial filters, but it'll give you a close enough idea.
Architechno, you never know. I noticed all my fans have the gap so I'm thinking the gap is beneficial. If you do want to try it, I would suggest double sided tape with only one side peeled off, cos the gap is about that thickness.