Sorry, I re read your comment as it didn’t sink in the first time, I know what you mean now about raising the wattage to see where the speaker will top out. In my current model I can raise the wattage to 20 and the cone excursion stays just under the red line, but the rear port air velocity is off the scale still, so lets say I wanted to model the speaker to handle the full 30 watts and fit a port in the box, to do that would I have to increase the box volume? Is that where I’m going wrong trying to increase the power in the same air space that works ok for 1 watt?
My plan for this speaker design is to make 5 of them and replace my larger surround speakers with smaller ones to fit a smaller room, so I want to keep the box volume small as possible (but I still struggle with passive radiator designs). My av reciever gives 50 watts per channel so I was thinking at half volume this design would work ok as it never gets turned up to full volume anyway.