I was saying do not use the foam backed process if the subs will be your primamry low end.
If you want to make them your primamry sub, find an 8" or 10" that will work great in a very small tightly sealed enclosure and find someplace (or someone better yet) and experiment with some fiberglass. Depending on how closely the side panels matches to the sheet metal, you might be able to use it as a mold.
As you can see from these pics you might not want the fiberglass hidden.
In these pics it's much easier to create and outward shape, unless you have some way of laying your 240 on its side

.
Actually, these both look like fun projects, but time and patience are the 2 most important tools.