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You might find it can sound better if each driver has its own box and its own port (PITA, I know).  I have had better success by tuning the port +/- below audibility and then using some whimpy foam to partially block the "too large" opening, as opposed to making the inlet smaller.

Does it defeat your purposes (in terms of efficiency) to use minimal stuffing or an internal hanging "curtain" in any of the boxes?  Obviously this gives the option for smaller boxes, albeit at the expense of some efficiency.

Basically, the more you try to do with/get from the port, the more of it you'll hear.

I've only tried steel with very small, sealed nearfield boxes, but it needs well-bonded, effective damping.  I used acrylic-modified stone mortar and felt in my DEBZs, which are 1 1/4" plywood.  The thing with steel is, it seems so "severe" and "unforgiving", certainly a great, grand, expensive PITA to build and to modify.

BTW, I agree that the math is a great place to start.

Best regards,
Paul S

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