1. Would a Bash 500 plate amp relieve the need to max out the volume on the receiver in order to get more performance from the sub?
probably but you should go for the Behringer EP2500
2. Would a 15” sub at the same volume have that much more impact?
probably, but i doubt with two kappas you'd need it
3. If you had two subs would you use two plate amps or a Behringer or Dayton 1000w sub amp?
Behringer EP2500
4. Does a downfiring sub have any less impact on the listener than the forward firing?
no, it's a room location thing and not a down firing or front firing thing
5. For movie listening, the volume is quite acceptable (from the mains) but I can’t turn up the receiver enough to get maximum effect from the sub. Are there any other options that I can look into rather than those suggested above?
6. Could the simple Kappa build be used as a down firing application?
yes, just make sure there's enough clearance