1. Is it possible to make the enclosures larger and use front ports instead of the rear ports so that they can be built into cabinets, without sacrificing the sound integrity.
In short, No.
But, ports could be relocated to the sides firing outward.
As for number 2: It does need to maintain the same front baffle design whether you lay it on its side or not.
The limitation to laying it on its side is that you are then limited to a horizontal coverage area that is equal to the length of the array.
Ideally, a curved array would be ideal.
As I was going to use the system for multi-channel audio I was also going to make the rears LS's.
Great idea.
My other questions relate to power handling and also SPL ratings, what are the maximums for both ?
Power handling is really high. 1000 watt peaks can be handled pretty easy.
High SPL's are pretty easy to hit too, and very cleanly. With just one pair you could hit clean peaks in the 120db plus range.