It lives!! The driver had about 18 hours break-in on top of the rude awakening I gave it yesterday.
Here is the finished baffle. I decided on a touch of bondo because I wasn't 100% happy with the sealing surface. I debated the wisdom of using bondo so close to the driver but I decided this is now my development sub and as such would make a great bonfire if it gives me any more trouble.
Did I say 10 minutes to change the driver? It was a RIGHT old PITA to get in there. It fought me every step of the way. Those t-nuts need to be bang on to get started and I really struggled to get them all started at the same time. It took me an hour to wrestle it in there... but there it is... home at last! Hurrah!
OHHHH FFS

It leaked in the same 3 places as last night!!!! Turns out it was leaking from the joints in the gasket which is in 4 pieces. There is only one thing I prefer about the 55-2421 and that's the single piece gasket.
WHHYYYYY? Infinity WHHYYYYY? Just put a note in there to put some sealer on before install and save us all a load of hassle!!
I was in no mood to take it out and fix so in a huff I put a dash of PL over each gasket joint. I was CRAZED at this point. I don't mind admitting I did a little dance, stamped my feet and shouted at the walls.
Luckily the PL worked and I chucked on the temporary cover. This makes a huge difference to the sound.
So first impressions are very good. Obviously I'm going to say that after such a traumatic couple of days but I'm totally convinced it is a better T18 for it.
It needs more power to drive it but goes waaaaay louder than the 55-2421. It seems to dig deeper as well and feels more effortless. It is very difficult to put my finger on why I think it sounds better. I'm going to spend a week with it... I reckon it will take me that long to figure it out.
One really pleasing discovery though it that it appears to be a smoother curve. My office is 12' x 15' and the 55-2421 sounded very up and down in volume during a sweep. The 860w sounds more uniform. Next week I'll make some SPL charts with REW and post them here. I guess I'll take one from my desk and another one 1m from the horn mouth in the middle of the room?
I need to figure out what makes a valid numbers. Can I choose a frequency, give it 2.83V, measure at 1 meter and use my SPL meter to declare my version of sensitivity or is this fictional bullsh*t?
If anyone wants me to take a measurement in a particular way let me know so I can make it valid.
I have REW, a checkmate IEC651 type 2 SPL meter and a Behringer UCA202 USB sound card so I'm probably right at the bottom end accuracy wise but I hope a can produce some meaningful figures for the common cause.
I'm away this weekend so I'll pick this project up next week.
Over all thumbs up!