Whew! I read the whole thread in one go last night. I think building the XO will be easier than that. Thanks to Pete and Zilch (and everyone else) for keeping this thing moving along. It looks like fun.
I inadvertently stumbled into the party yesterday. I made my second stop of the day at the thrift store (it's very close to home) and found a pair of Minimus 7s. I'm a little embarassed to have paid $19 for them, but the ones I got (white) are pre-A (i.e., no suffix) and in pretty nice shape cosmetically and sound-wise. I was impresed at how good they sound for such a small speaker. But, as evidence that I'm taking baby steps on the path of audiophilia, I did in fact find them fatiguing after a while, even with the bass turned up. I was glad to switch back to my $15 Nova-8s, which I kinda enjoy more than my $500-ish DIY SR71s (Zaph Audio design). The rest of the family preferrs the bottom of the stack, thank goodness.
I put in an order to Madisound for caps and resistors. Even though PE has the 1.0 mH inductor on sale for like $3.85 right now, I'm nothing if not a CSOB. So I'm going to try a little something different.
I tend to keep a lot of stuff "just lying around". Years ago, I tore apart a microwave oven transformer and kept the core. Here's the top part (the I's) with 50-ish turns of thin magnet wire.
That's 6.48 mH, measured at a frequency of 1 kHz. The plan is to split the top part into halves or thirds. It's a stack of laminations, so pretty easy to split. Then I'll wrap the cores with some 14 gauge enameled wire I have (laying around...) One nice thing about this particular transformer core is that there are holes through all the layers (barely visible in the lower part of the "E's" in the background.) So it should be easy to rig up some kind of mounting scheme.
I should say that I have *some* knowledge of magnets and transformers, but I'm no expert, especially where "practicalities" come into play. There could well be some pesky detail that makes this whole idea fall aprt. (Any ideas?) But I thought it would be fun to try, and if it saves me $8 plus shipping, there's that.