@clio09 Then I will say it. John Hunter is wrong. He is interested in selling as many subwoofers as he can and not in designing the best possible subwoofer.
@tomic601 @erik_squires @phusis This is not all that complicated. Most of you are right, you just need to be able to explain it better.
The speed a woofer cone travels is a sinewave function. The average speed to produce a note at a given loudness is a function of size. The smaller woofer has to travel farther to displace the amount of air required to produce the note at that volume so it has to travel faster. The speed is not an issue but "farther" certainly is. Dynamic speaker suspensions are linear only for a very short distance. At some point, depending on the suspension's design, the suspension becomes progressively stiffer until it can not move any farther without ripping it apart. Because of this non linearity distortion increases logarithmically with excursion distance. This is why larger drivers or multiples of smaller drivers have lower distortion levels. They do not have to move as far so they do not have to travel as fast. Bigger is always better, not worse!
Boominess has two causes, the subwoofer running into the midrange and a resonant, shaky enclosure. To keep the sub out of the midrange people historically lowered the crossover point. This is a problem for a number of reasons. Much of the impact or dynamic factor comes at higher frequencies in the 80 to 100 Hz range. You want the sub running certainly up to 80 Hz and I will go no lower than 100 Hz. The solution to this problem is running steeper filters, not lowering the crossover point. The problem here is analog filters are terrible at this. You have to have a digital crossover then 8th order and higher is no problem. Running that high a high pass filter for the mains is mandatory or you will have a hot mess. This is advantageous anyway from a distortion and headroom perspective.
Making an enclosure that does not shake or resonate is a very hard problem to solve. The easiest part is using a balanced force design. You put a driver in opposite ends of the enclosure running in phase. The Newtonian forces then cancel out. Making an enclosure that does not resonate is much tougher and very expensive, more expensive than most commercial manufacturers will tolerate because they have to remain competitive. This is the reason I make my own. You can see a picture of the final versions before finishing. I plan on doing a full pictorial of their construction so others can copy them if they are inclined. These will be high gloss black. The walls are 1 7/16" thick. Plywood was used instead of MDF because it is stiffer. The individual sections are only 4" wide. The subs sit on the floor horizontally on two spikes right up against the wall. They lean on a special pad. Because they do not vibrate at all nothing will get transferred directly to the wall. Small sealed enclosures are always best with subwoofers but you have to have a lot of power and high resolution digital EQ. Then you can make any sub run flat as a carpenters dream.
The last problem is time alignment and this is best done with a digital crossover and room control which is really speaker control.
With subs running up to 100 Hz and cut off at 48 dB/oct or higher, if you want more impact just turn the sub volume up a little and you can have it without affecting the midrange or treble. I run mine hot by about 6 dB which gives the music a "live" feel at less than ear shattering levels. A great subwoofer system is more felt than heard. In reality, the faster a subwoofer cone has to move the worse will be it's performance.