Well, you got it right //content.invisioncic.com/y282845/emoticons/mad.gif.c18f003ab0ef8a0d9c27ca78d77a6392.gif
I took a couple subs out and played it a low volume and each sub sounded fine. I could also stick my ear in the box to listen to the 3rd and 4th subs and they sounded fine. I noticed the loose flapping sound would change as I moved the box around. It sounded like the box was somehow making this noise. There was nothing loose in the box so then I started holding down different panels. I squeezed the top and front panels together and the noise automagically went away. Let go, and buzz buzz buzz with less output. I guess the top panel is barely seperated from the front panel and the silicone from the inside blew out so the top panel vibrates against the front panel and enough air escapes. The seperation must be so far across that it has a big impact on the output. I didn't think this was happening at first because the box is coated with Fleckstone and I didn't see any cracks in the paint.
This is why I don't build boxes for people for money. But, I've done enough for myself that this shouldn't have happened. Guess I'll throw some nails on that top panel in addition to the screws and if that doesn't help I get to start at square #1 on the box.