Steve,
These are my thoughts on OB design. There are other methods but these have worked for me. I believe that this approach works well for both passive and active crossover options.
Question 1 How do you find the size of the baffle? Trial and error? or is there a magical figure?
I find the size and shape using computer modeling. But since this is such a quick and easy build, the cut and try method will also work if you don't mind using up some wood or cardboard.
Question 2 What driver parameters determine what driver would work in a OB?
I believe you need to think in terms of a two way design as a minimum. I like larger pro woofers with an fs of about 40 and a Qts of greater than 1.0. This will allow a floor standing OB design that is about 20" in width by 32 to 48 inches tall. If your Qts drops below 1.0, the bass will be rolled off. You will not get below 40 Hz with a flat reasonably sized OB without some EQ even if your driver has an fs of 30 Hz. To go lower passively requires an H or U frame dipole.
Question 3 Is there a computer program to aid in designing OBs and where do I obtain it?
I use my MathCad worksheets. I am not aware of any other software that includes all of the features that are in the worksheets.
Some people use the EDGE or XBaffle programs but they only give you part of the solution. As long as you recognize this and adjust the design to account for the missing elements these will probably work well.
Question 4 Is a fullrange speaker better in a OB than a multi driver configuration?
I believe that as long as the bass below 200 Hz is handled by a separate woofer that a full range driver or multiple drivers can work well. By crossing over in the 200 to 300 Hz range you can use the hump in the baffle response to your advantage. If you crossover higher then the SPL response will have a 3 to 4 dB hump in this frequency range .I personally like full range drivers crossed over to a driver like the Eminence Alpha 15A, that is my current recipe.
I am sure people can argue some of my basic comments, but that is what works and makes sense for me. You can't beat basic physics. There are two articles on OB design on my site and more on the way.
Hope that helps,
Martin