since we're still on the topic and all, if you cant afford aero ports (or dont want to drop $40 on a single 6" port). i found this from Team Toxic Bass. basically a way of making a flared port (only on the exit side) on the cheap, using PVC pipe, and an extra piece of MDF. however you do need a router, and a circle jig to get it right. if you have it, you should be golden.
here is the link, although i have included the pictures that deal with the port design in this post linked from my photobucket, just incase TTB decides to delete that webpage.
http://www.teamtoxicbass.com/~pete/car_audio/compvr_bass-reflex/index.html
After some careful analysis of the trunk / cabin transfer profile, I arrived at a simple off-axis bass-reflex as the most suitable loading approach for the CVX to perform along the customer’s listening preferences. As rudimentary as this project is, I still like to improvise with a little bit of “flare”. After the panels are cut, I prepare a 10.22” length of PVC along with a 6” x 6” mounting frame.
The port is then fitted into the frame cut-out and held in place with contact cement. Note: When cutting PVC, it is best to save the sanding for after the pipe has been flush-mounted onto the adjoining surface.
Next, I align the frame with the upper enclosure panel and dry-mount it firmly with a set of four screws (no counter-sinking).
Then it’s simply a matter of flipping the panel around and tracing the port’s inner diameter with a 1” round-over bit for an outer flare diameter of 6” (equivalent to that of an AeroPort).
Once I’ve assured that everything aligns, the frame is glued in permanently for a perfect seal along the double-stack. As an additional anti-air leak precaution I circled the MDF / PVC merge point with a ring of silicone.
With the panels disassembled, what would otherwise constitute a rather awkward and hard-to-reach aspect of the construction was made quite easy. Now onto the box assembly: