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Sounds like you know what you're doing. Good job. Free air stuff is exactly what I meant. And you've done all the right testing...I'll just clam up now because you're doing a great job. Corners. Feh. Difficult to work with even though I agree that you can get some horn loading benefit out of them. Oh well.
Another testing method I remember reading about which made me scratch my head: put the sub where you would sit, and then put yourself or the meter where you want to have the sub. The room modes, I believe, can be affected in either direction and this can give you a rough idea of where a good starting place might be. I've never tried it, but I think it has some merit.
Finally, I have herad some high end stuff with dual pairs of woofers in separate boxes. Yes, two boxes with double the drivers. Instead of building a monstrous box for all four drivers, maybe two boxes with two drivers each might keep the box size small enough and maybe a little more manageable. No, tuning two boxes in the room is not easier...pretty obvious it would be tougher, but it would keep from having to deal with a coffee table sized unit.
...on the other hand, that would be pretty cool...I seem to remember some high end speaker mfr making a sub that was obviously built to be in a large room because it was enormous, but I dont remember who it was...
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