I have not read through this thread yet, so I apologize in advance if I'm commenting on topics already completely worked out... but here's my kneejerk response anyways
I have found that speaker chamber size, capacity, and back-venting to be extremely important. Back when I made my first saber (proto1 with clash flash) I spent much time playing with the speaker chamber size and placement. I could hear big changes in overall tone.
Volume also was effected greatly by these changes. I was building my first few sabers with no back speaker venting. Just venting at the bottom of my sabers. Then, when I was working on Proto3B I started noticing how LOUD the saber was when testing it mostly disconnected. I had the bottom of the saber together but the top of the hilt was off and the middle tube was just open with some wires coming out. The volume was much more intense.
So on Proto 3B I drilled some venting holes in the middle of the hilt, above the battery. The difference was immense, it went from being much quieter then my Proto3A saber, to much louder. Additionally, since I now had holes in the hilt I went ahead and put some blink LED's in there to add to the effect. It worked out really well.
Long story short, I do think speaker chamber size, and shape are very important. Additionally, I think back-venting can also lead to really good results in some setups. It sure did for me.
My final comment on the subject... I would personally avoid giving out solid rules for building your speaker solution in your saber. You might do everything the same as another guy, but have one minor physical change that just alters the entire effect. I can easily see something working VERY WELL for one saber, and making it worse in another. It's a case by case basis so any discussion should probably revolve around understanding basics of sound... then each saber smith figures out how it applies to EACH saber they are working on.
Cheers,
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