Too much MDF... help me build some boom

Long story short, I have a buttload of MDF, mostly 3/4" but also some 1" and some 1-1/4" Then last week I received a couple crates of high-end lumber that was packaged in 3/4 MDF, so I now have two huge 72" x 64" sheets to add to the pile.

I work for a performance theater and I've been craving more boom than my single Yorkville gives.

I have a very large shop

1 + 1 = 2. Let's make booms.

Wants:
Size - not really an issue. For once I have plenty of space for something with volume, so something like a tapped horn or bandpass isn't out of the question.
Freq - basement. The rest of my pre-amp equipment is all good for down to at least 10hz (not that I need that low), and there is just something about a good shake from 17hz when I have a thunder sound effect. The Yorkville does great in the upper 30s, So shall we say 18-40hz?
Budget - technically zero, but I have the MDF and materials to build it. Drivers will likely cost money, but I have a guy who might want to trade me some drivers for a snake I have. Having said that, if I have to buy drivers it seems like a huge jump to go to 18s, so maybe 15s would be wiser.
Amp - up for debate. I would love to splurge on a plate amp. Running XLR to it will be easy. Running speakon from the rack will be a pain. Truthfully I could probably just do a rack mount amp screwed to the box somewhere.
Appearance - ugly. It will be hidden under the seating risers, or possibly even under the stage.
DB - doesn't need to be insane. Most of what we do is live performance theater and musicals. We do occasionally have musical concerts, so having some louder potential will be nice, but no need to make it louder than the Yorkville.

So let's talk. Links? Ideas? Designs?
 
Isn't it easier to find a low FS 18" though?
The Dayton Audio PA460-8 is 130$ 29hz fs, 0.33 qts and should work in a proper horn?
Will be big though.

Says they cost too much........and this driver has too high an Fs for an 18 Hz horn WRT power handling. HR calcs its 400 W gets trimmed to 5 W, so won't even hit 115 dB/m/2pi without exceeding Xmax a bit.

Meets the 'large', consume materials, specs though at ~ 785 ft^3 22,221 L. 😀
 
Drivers that could do that will cost some money, the Dayton UM15 or UM18 drivers could do it, but cost a few hundreds. Pro audio drivers don't go that low i'm affraid, or only with extensive eq with dsp which also raises distortion. If you go pro audio drivers, it will also be the more expensive drivers (B&C, 18Sound, ...)
 
to make 18Hz audible you will need high SPL. Multiple 18" or 21" horn subs under the stage, you will also want low Qts high excursion drivers (expensive). Fabric London uses 18" drivers under the stage for sub in room 1. They will be very large; as an idea here are some commercial subs that don't even go that low (and are already... large):
Hennessey Sound Design - SUB WOOFERS

*you could also do very low tuned reflex as is done in home theater with smaller box size but this will be less efficient and so require more drivers.
 
Says they cost too much........and this driver has too high an Fs for an 18 Hz horn WRT power handling. HR calcs its 400 W gets trimmed to 5 W, so won't even hit 115 dB/m/2pi without exceeding Xmax a bit.

Meets the 'large', consume materials, specs though at ~ 785 ft^3 22,221 L. 😀

Indeed... Quite difficult to meet these criteria without spending money on drivers... Quite a respectable size though, and actually a proper sub to handle sub-20hz content, which is rare as many here seem to make stuff from 3-8" and call it "subwoofer".

I think you'd need a couple 21" to be happy... Eighteensound 21LW1400?