dodgey,
I did a bit of car stuff when I was younger too. ;-)
Yes, the internal structure makes the box stiff and strong and stops the box resonating and flexing. Apparently it's essential.
The plans are from here-
http://www.adireaudio.com/Tech%20Papers/shiva_apps.htm
It's the 142.5 liter vented enclosure. Mine's being used on it's side so it's front firing. I like to see the driver and it was a bit easier this way, no need for feet.
I've listened to DVD's very loud, (not far off reference level), I've never experienced port noise. However if I play low frequency high amplitude tones (in short bursts, I don't want to melt the voice coils) it does chuff,
(it also gives you a headache for 3 hours.)
As you know, if port diameter increases then so does port length for the same tuning. I built my sub from the plans mentioned above so I wasn't worried about port noise and tuning. I like the idea of using a tried and tested design (especially as I'm still learning).
It's powered by a 300 Watt mono amp from
http://www.bkelec.com/ (in the Modules & Hybrids section- OMP MF300) and I'm also using the Sub Bass Filter. A little soldering is involved.
As the plans are from the US the measurements are imperial. The plans use 3/4" MDF which is not common over here. Fortunately Arnold Laver
http://www.timberworld.co.uk/ (main branch is one mile from me) stock it. It's about £20 for a 8' x 4' sheet. I paid a local carpenter £40 to cut all the panels to size.
In the US SonoTube subs are very popular having various advantages over tradition box subs-
http://members.tripod.com/~terrycthe...um/page12.html
You can find this stuff in the UK with a bit ringing around. I think my next years project will be made out of this. The stuff I found was called Rapidobat, BRC supplied it.
The high black gloss finish was achieved using car spray. The box was sanded, undercoated and sanded then spayed, then wet sanded then spayed again. I used about 10 cans at £5 a can. Next time I think I'll use a different method. High pressure plastic laminates, veneer, Covered in fur? I don't know.
If you search on the various US forums
http://www.hometheaterforum.com/ you'll find various finishing methods discussed.
Total cost was about £450 with 300 Watt amp, (and that's also including the £40 carpenters fee for cutting the panels and £50 of paint.)
And it does sound very good.
Hope this helps you to get started dodgey ;-)
Cheers.