Ok, a quick update.............
Sub and panel arrived yesterday, this morning I faxed a cutting list to my local wood yard and picked up the MDF for the sub (cut precisely to size, the whole lot came to €16 - less than £12)...... 400mm x 400mm x300mm internal dimensions, about 50l by my reckoning. taking account of the volume of the speaker and the amp panle it should be still well above 45l internal volume. The only cutting I had to do was the holes in the internal brace, holes in the two front pieces for the speaker and the cutout in the back piece for the amp panel.
Assembled in a few hours (half day off for the occasion !), a mate (Vexorg) dropped by around tea-time to assist with final assemby. Packed it with polyester filling (No data on exact weight of filling - Mrs. Ritz donated an old pillow to the cause), and was careful at the back near the amp panel to staple it in such a way as to keep it well clear of the internals of the amp.
We hooked it up quickly for a test-drive (in a rush of enthusiasm, like an idiot I connected it to the subwoofer IN, instead of the sub out, you should have seen my face as it stood there mute instead of pumping out lots of lovely bass.....

). WE quickly sorted that out that moment of madness and............................
Well folks you can believe all you've read about this diy sub formula............... it sounds smashing - tight controlled bass (and plenty of it. I haven't even started trying to locate it well or mess with Avia tones, I just set the Low Level Gain to 12 o'clock, the frequency to LFE, and ran through ATOC (opening and Asteroid Belt), FOTR (Ring Drop - Whoa !!) and Master and Commander - Cannon Balls out of the Fog (CH. 4).
Vex and I sat there with very silly grins all over our faces (including wondering what it would be like with two subs of this design...... OMG...)
Later playing the Eagles Hell Freezes Over it was superb, there is no dominance in the bass, it's there (in spades if you want) but compliments the rest of the soundtrack perfectly. I know practically nothing about the esoteric side of subwoofery but I would describe this as "well integrated". I will be interested to try Avia and a sound meter on this and see what it shows up.
To say I'm pleased would be an understatement..... I'm very well chuffed.
The cabinet needs to have countersunk screwholes filled and some sort of finish applied (black of some description allover, it doesn't really matter, TBH, I hope to have it out of sight behind my screenwall). This was a very effective way of spending four hours, no mistake about it.
I'd like to say thanks to the originators of this DIY project - RTP, take a bow.... and also much thanks to the members who've posted on this thread with advice and encouragement.......... I know I said this would be a one-off, but I've gotten a serious buzz out of the result and am off to have a little think about what I might concoct next.......
Sean G.