It sounds like all the boxes you've had were too large. When you tune as low as you are, most subs aren't designed to thrive down low, so it will level it out. Alternatively, a smaller box will level it out with a higher tuning.
This might be the case, because most of my boxes are usually on the large side of what the manufacturer recommends.
Just stating my personal experience. So whats a better way to simulate or design what size box is needed?