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Originally Posted by bestatchess
Finally, I was reading on the net and it was recommended in one article to sandwich two sheets of 3/4" mdf together for the face of the box with the mounting hole for added strength. Is that advisable or just a waste of MDF and potential box volume?
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I agree. You will not need two pieces of MDF sandwiched for the face. A subwoofer of this low of RMS power handling won't have any flexing issues if you use 3/4" MDF on a small box. If the face of the box was larger or the power handling greater, than this is a good idea.
Also, every installer will tell you something different... but in my experience, the more surfaces the bass frequencies have to bounce off of before reaching the listener, the better. For instance, you don't want a woofer pointed at your head. If you had a box in your trunk, you would want it to face the rear of the vehicle, slightly up towards the deck lid.
In our case, we are so limited due to space constraints. If someone were willing to sacrifice the back seat, you could build one hell of an SPL vehicle. But we need our back seats. So, with the woofers firing down, it will probably sound better as long as the box is properly anchored to the floor. This will sound much more tight.
As far as the .4' vs. .6 on the cubic foot question, why not build your box as small as possible.* Just make sure the magnet is .25" or more from the inside rear of the box when the sub is mounted. ** The little bit of flex might cause the rear of the magnet to contact if you are closer.
*If .4 cubic feet ends up being too small, you can ALWAYS add PolyFill to fool the subs into thinking your box is bigger.
If you build a .6' box, you will not be able to make it smaller (unless you cut it up and try again).
**Tip: If you have built your box to the tightest tolerances of the mounting depth specs, and you are not sure if the sub magnet contacts or how far it is from the inside of the rear of the box, place a small chunk of clay or silly putty on the area of the bottom of the magnet most likely to contact the inside of the box and press the sub all the way onto the box as if it were being screwed down. Pull the sub out. Peel the clay off carefuly as to preserve its width and you will be able to see how far the magnet is or if it is contacting the box inside.