Well, I have not done too much with FG, and after reading all of this, I am not too sure if I ever want to again. The only experiments I have had (4 total) all turned out just fine because I followed all directions as well as I could, I did have one warp and I had another that I think the mixture was too hot so it had all kinds of indentions, and holes from the bubbling and poping and such.
My worst box experience came with my first car, I had an 85 dodge daytona and I put 2 RF 18s in a self-designed 7th order bandpass (I think it is 7th order, baiscally I had the 18's wired parralell and separated in their own enclosures, and all four were firing into one single chamber in the middle with a monster vent)(built with 3/4 MDF I used a total of 3 and a half 4X8 sheets, just to give you an idea of the weight); this thing was a freaking monster, I took out my backseats and it streached from the back window of the hatch to the back of my front seats with them pushed forward a couple of inches, I started designing it before I even had the car, and I took some serious time planning and building it, and I even made a full size replica out of cardboard, just to bdouble check my math. and so when it was all built I tried to fit it into my hatch, and the sides were too wide to clear the opening for the hatch by 1/8 or an inch on both sides even with the trim off, so I had to pull this insaine-ly heavy box off of the lip of the hatch opening and use a circular saw to cut some off the top, side corners, then with a lot of getting a running start and slamming into it with my shoulder it finally slid in (after breaking the plastic panels at the far back (below where the hatch latches)) then when I went to shut the hatch I realized that the back end was too tall for the slope of the window, so I had to cut an inch off of that with the circular saw inside the car (because there was no way in hell this thing was ever comming back out of this car) and finally it fit.
So after that I owned the car for a year and decided to buy a Blazer, because I needed more room for more subs (always more subs). so I sold the car, but of course I wasn't going to let my subs go with it, and with the boxes in the car there was only about 8 inches clearance between the top of the box and the roof of the car I couldn't just unscrew the plexiglass window and remove my subs, so I had to break out the circular saw once again (never let a 16 year old have a circular saw ) and had to cut the boxes out with that, so when I sold the car it had almost completely crapped out, and wasn't worth more than $300 in good condition, so I sold it to a guy I know that owned one at the time and was going to part it out, so I just threw the back seats back in and left it with a nice 4 inch coating of sawdust on everything.
So with that all said, who wants to buy a car, or have me build them a box?... any takers?... This is definetely one of those learning experiences, you know, measure twice cut once, not measure once cut 10 or 15 times.
eh? what did you just say?