Joe,
I am doing the 1"x1" squares. But I have seen some that have done slightly different patterens or grooves throughout the plenum. I think it is all about air moving, could be circles I guess? As far as the bleeder board, it looks like you skim a little off side number one, then glue it down to the plenum. From what I have read here on the forum I think the best way would be to glue all around perimeter and in between the zones. (That is the way I understand it.) Then skim a little off the top side and ready to go.
My plan is this:
I have just redone my table base last week. I took it back to the stringers and started with a 3/4" MDO bolted to frame. Then added Rockler ttrack and screwed it down. Then glued down 3/4" MDF in between the tracks and skimmed .005 off the surface until flat.
Now, for my vaccum. I plan to build a box, cut one hole in the far end of my table for the PVC, and make a BradyVac one piece drop on board. I am keeping it small for my first try with vaccum hold down, After I work out the kinks, I will then probably make a 4'x4' Plenum and bleeder board for the far end of my table that will stay on the table most of the time.
I rarely cut things over 4'x4' so I figure most of the time I will have all the options available. Working on setting up Jigs, gonna start zeroing off my limit switches with custom c3 comands. I am trying to stop running my Bot like a cave man.....LOL
Dave