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We have a 200amp cnc plasma table at work so it was fairly easy for me. I had one of the guys draw them up for me.

There is a lot of waste because of their shape so I made them out of 1/2" steel instead of the 5/8" aluminum the originals are made out of.

A 5X12' sheet of 1/2" aluminum would have cost me $1500 and would have been able to cut maybe three or four sets out of that. I never checked what 5/8" aluminum cost. They still ended up being expensive to make out of steel.
 
Some suggestions:

The crossovers have some level adjustment switches--apply a couple of small sprays of DeoxIT on those switches and work them back and forth.

Remove the existing fuses from the crossovers (3 per each speaker), clean the fuse holders and replace (anew) the fuses with the proper ratings* See image below.

Test the drivers with an ohm meter for a complete circuit.

The crossover has a "program card" in it that is interchangeable with other versions to bi- or tri-amp the speakers. I have the all-in-one card (most common). Remove and clean the connectors (with DeoxIT) and then reinsert. Also, remove the wire connectors carefully from the plug and apply DeoxIT there too.

The drivers can be rebuilt by Richard So at: ads_speakers@yahoo.com Richard rebuilt the hard to find tweeters for me and they sound and look like new--very reasonable price too!

BTW, I did all of this and have not yet recapped the crossovers--my speakers sound beautiful!

Here's an excerpt from the Owner's Manual regarding fuse ratings:

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