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A buddy of mine wants me to design and build him a downfire box for his ext cab ranger. My question is how much is the minimal amount of distance you should leave between the sub baffle and the floor?

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as long as a full excursion it doesnt hit the floor you will be fine exact distance depends on subs abilitys.

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Depends on your goals, personally any less than 3" of clearance beyond the sub travel isn't enough but my goals are probably different than yours.

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