Hey 610 - a slightly smaller box will sacrifice a little of the very bottom end frequency response, but more importantly will affect the port tuning quite a bit. This can potentially cause a resonance at one particular frequency, making it really boomy on one particular bass note. (and some like it this way!) Also be careful about stuffing too much damping material in there, because it takes up a little of the volume itself and subtracts from the total capacity.
Port tuning is a pretty fine balance between several parameters of the driver itself, the volume of the box, and the port tuning frequency. That's why I have to have a bit of a chuckle at these generic subwoofer boxes that can be bought from just about anywhere, with the ports and everything already fitted. "Just choose your sub and screw it in..." But of course, that means neither the box nor the port are properly tuned for the driver.
There are a lot of programs out there to help with port tuning, but you have to feed a few parameters in to get the figures out. Many of the lower end subwoofer drivers have rather arbitrarily calculated parameters supplied, if at all!
Hope it helps anyhow. Cheerz! :thumbsup: