I'm pulling my hair out on these crossovers. Just a quick update...
I tested the woofer by itself, out of the cabinet, and it still has that dip we talked about earlier. There is just no way of getting rid of that. It was the same for the originals. Aside from that dip. I was trying to get the FR as smooth as possible from 35 to 15Khz. When doing that I have to smooth the graph quite a bit, so even though those dips appear to be gone, they are still there.
I took the mid coil out of the circuit and started all over. This time, when I hooked the drivers to the Klipsch AL' network, that flatness was not there anymore. But when adding the coil back to the AL' electrical path, no improvement. Figures. Murphy and his laws.
Anyway, I started playing with XOVER3 Pro to model what the network "should be". So I tested the woofers and mids to get the FR, T-S and impedance curves imported into the program. All that being said, XO3 wants to replace the 2.7mH with a .5mH. You may remember saying that the .5mH gave me the flattest curve when I as testing earlier. But nothing XO3 recommends is even close to what Infinity designed. When I plug the actual values used by Infinity in, the resulting curve is pretty ugly (in terms of flattness), looks similar to the one when I actually measure it. The one big difference is that in XO3 I can't get the initial level of the bass to match what it actually looks like. It is much higher than what it shows. Must have something to do with the box design. Maybe that port between the legs. That won;t affect the overall curve, where the mid crosses, but it seems I may need more time with the product to really understand if I am doing it right.
Anyway, that's where I am right now. One speaker is apart (Leaving the other in tact so I can compare sound later). Still trying to find the right combination pf parts/pieces to give the curve and sound I want. I just about gave up, thinking the original crossover sounds good enough, but I still have some drive left to experiment a little more... I believe they can sound better.
The other problem I have is the tweeters. They are so freaking efficient. I really hate to add a lot of resistance just to get them to level out. So I'm still contemplating replacing them with some Soft Dome Tweeters. Since I do use these primarily as surrounds, I'm struggling with how much additional time and money to put into these. I'm getting pressure to get the surround sound back up so they may just go back the way the were and I can try it again later after I get a better handle on XO3.