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Designing a custom crossover.

John Carr

Active Member
I have been designing crossover specifically for the drivers I have. I have never done this before, but I know that the goal is to flatten the response fairly well. I did input my specs into a crossover calculator and designed it in xsim, with a few tweaks. Does that look like a good response in yall's opinion?
 

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Hello. I'd say that dip or "valley" at 700Hz is something not desirable. I'd move the woofer xover higher or the mids lower.
 
Hello. I'd say that dip or "valley" at 700Hz is something not desirable. I'd move the woofer xover higher or the mids lower.
That's a good point, but I don't have much of a way to do that both the mids and woofer have a slight dip there in there responses.
 
A smaller inductor will move the woofer higher. Or a larger capacitor at the mids. But you need to be sure the mid range drivers can go that low. If not, raising a bit the woofer would be the safest. Try the simulation with a smaller inductor. Also, real world measurements will show you what's happening. You can replace a driver (woofer or mid) with a dummy resistor when measuring, that way you can see the real crossover slope of the other driver. And check how they cross each other.
 
A smaller inductor will move the woofer higher. Or a larger capacitor at the mids. But you need to be sure the mid range drivers can go that low. If not, raising a bit the woofer would be the safest. Try the simulation with a smaller inductor. Also, real world measurements will show you what's happening. You can replace a driver (woofer or mid) with a dummy resistor when measuring, that way you can see the real crossover slope of the other driver. And check how they cross each other.
That's a good idea. When the components come in, I'll measure the responses individually. As for the midrange, it can go that low because it's intended to be full range.
Thanks for the idea!
 
I did input my specs into a crossover calculator and designed it in xsim, with a few tweaks. Does that look like a good response in yall's opinion?
Looks like you're rapidly gaining insight into the fundamentals of a 1st order network. Hafta agree with @elnaldo that performance will likely suffer from a 10dB depression in the midrange. Assuming you're still using 8Ω GM-85/8 drivers, I'm curious why you have them wired in series for a 16Ω load rather than parallel for 4Ω. That alone reduces relative output level. You could try setting them in parallel in Xsim just to see how that compares:

Parallel Mids.jpg


"Tune" values of C2 and L1 as shown above to set bandpass crossover frequencies similar to where they are in the series configuration. Those corner frequencies appear to be roughly 250Hz on the high pass side (capacitor) and 2800Hz on the low pass side (Inductor), based on factory published impedance curve. Though actual driver samples may vary.

I'm also curious about the woofer inductor value, which seems high for a 4Ω woofer. Big woofers with their large, inductive voice coils typically have a rapidly rising impedance shortly after resonance. Published resonant freq. for Jensen J12W is 30Hz. If impedance settles back down around 4Ω by 60Hz before it's inductive climb, then crossover frequency could actually be that low, or thereabout:

J12W LoPass L.jpg

So another thing you could experiment with is tuning that inductor value down to see if it adds more energy higher up in the bass region.

Xsim is an excellent tool for delving into this subject. Some expert members here appear able to master this stuff in their sleep. For the rest of us, it's fun to work up a circuit from what we think we know of theory, then watch the results inexplicably defy reason.

It's all about the learning! :D
 
Looks like you're rapidly gaining insight into the fundamentals of a 1st order network. Hafta agree with @elnaldo that performance will likely suffer from a 10dB depression in the midrange. Assuming you're still using 8Ω GM-85/8 drivers, I'm curious why you have them wired in series for a 16Ω load rather than parallel for 4Ω. That alone reduces relative output level. You could try setting them in parallel in Xsim just to see how that compares:

View attachment 2526049


"Tune" values of C2 and L1 as shown above to set bandpass crossover frequencies similar to where they are in the series configuration. Those corner frequencies appear to be roughly 250Hz on the high pass side (capacitor) and 2800Hz on the low pass side (Inductor), based on factory published impedance curve. Though actual driver samples may vary.

I'm also curious about the woofer inductor value, which seems high for a 4Ω woofer. Big woofers with their large, inductive voice coils typically have a rapidly rising impedance shortly after resonance. Published resonant freq. for Jensen J12W is 30Hz. If impedance settles back down around 4Ω by 60Hz before it's inductive climb, then crossover frequency could actually be that low, or thereabout:

View attachment 2526075

So another thing you could experiment with is tuning that inductor value down to see if it adds more energy higher up in the bass region.

Xsim is an excellent tool for delving into this subject. Some expert members here appear able to master this stuff in their sleep. For the rest of us, it's fun to work up a circuit from what we think we know of theory, then watch the results inexplicably defy reason.

It's all about the learning! :D
This is some really interesting stuff that I'll try out, but I will tell you that I am using Dayton Audio designer series 12inch woofers now.
 
Looks like you're rapidly gaining insight into the fundamentals of a 1st order network. Hafta agree with @elnaldo that performance will likely suffer from a 10dB depression in the midrange. Assuming you're still using 8Ω GM-85/8 drivers, I'm curious why you have them wired in series for a 16Ω load rather than parallel for 4Ω. That alone reduces relative output level. You could try setting them in parallel in Xsim just to see how that compares:

View attachment 2526049


"Tune" values of C2 and L1 as shown above to set bandpass crossover frequencies similar to where they are in the series configuration. Those corner frequencies appear to be roughly 250Hz on the high pass side (capacitor) and 2800Hz on the low pass side (Inductor), based on factory published impedance curve. Though actual driver samples may vary.

I'm also curious about the woofer inductor value, which seems high for a 4Ω woofer. Big woofers with their large, inductive voice coils typically have a rapidly rising impedance shortly after resonance. Published resonant freq. for Jensen J12W is 30Hz. If impedance settles back down around 4Ω by 60Hz before it's inductive climb, then crossover frequency could actually be that low, or thereabout:

View attachment 2526075

So another thing you could experiment with is tuning that inductor value down to see if it adds more energy higher up in the bass region.

Xsim is an excellent tool for delving into this subject. Some expert members here appear able to master this stuff in their sleep. For the rest of us, it's fun to work up a circuit from what we think we know of theory, then watch the results inexplicably defy reason.

It's all about the learning! :D
I did the change so that I might see the difference:
TM xover 3.PNG
Not sure if it's much better.
 
Last edited:
Not sure if it's much better.
It might not be done yet, but overlaying before and after curves shows noticeable improvement.

B4_After.jpg

the Beige portion reveals a generous frequency span across upper bass and midrange that has significantly improved.
The wide, deep dip that had bottomed out at 700 Hz is now a narrow, shallow dip by comparison, that has shifted to ~ 1300 Hz.
Lost a small amount of output (Green) between 1200 and 1800 Hz.

Depending on what's causing the dip, a fix might be as simple as adding a contour network, or further tweaking crossover points.

Is it possible you can post zma files for the drivers?
 
It might not be done yet, but overlaying before and after curves shows noticeable improvement.

View attachment 2526916

the Beige portion reveals a generous frequency span across upper bass and midrange that has significantly improved.
The wide, deep dip that had bottomed out at 700 Hz is now a narrow, shallow dip by comparison, that has shifted to ~ 1300 Hz.
Lost a small amount of output (Green) between 1200 and 1800 Hz.

Depending on what's causing the dip, a fix might be as simple as adding a contour network, or further tweaking crossover points.

Is it possible you can post zma files for the drivers?
Do you mean the FRD files?
https://drive.google.com/drive/folders/1MQ9umGqdgx6Ir15D-Q3cNwjqwF7OFo8V?usp=sharing
 
Got the files, Thanks!
Had to pause for an anniversary celebration yesterday (seems to happen every year ...). Got to play this afternoon though. Kept struggling to get the midrange level up. Viewing the bare driver in XSim using the .frd file shows average SPL below 80dB and an 85dB peak at about 450Hz:

GM-858 85dB.jpg

Published literature shows the same curve, but 10dB higher:

GM-858 95dB.jpg

Adjusted sensitivity up 10dB in XSim to reflect published specs and it behaves much better with the other drivers.

GM-858 95 risen.jpg

Tweaked things a bit and got a reasonable system response curve ...

JC3 FR.jpg

... with this circuit:

JC3 ckt.jpg

System impedance here never dips below 6Ω. Had wrestled with low impedance issues in earlier attempts.
Part of the challenge (for me) is a tweeter that plays down to ~ 1500Hz and a woofer that works up to the same -- they seem content as a 2-way system. That prompted 2nd order filters for tweeters and woofer to make space in the middle for the Goldwoods, which are connected inverse phase.
 
Here's a view of individual curves. Note that only one midrange and one tweeter are shown. Try to show their twins and the curves just overlay exactly, with no change to the graphic. DB gain from paralleling those drivers is reflected in the System curve.

JC3 curves.jpg

Pending actual, verifiable sensitivity performance of the midrange drivers, this could be a place to start for further refinement. It's about the limit of my experience level. There are vastly more knowledgeable members capable of devising a more elegant solution.
 
Here's a view of individual curves. Note that only one midrange and one tweeter are shown. Try to show their twins and the curves just overlay exactly, with no change to the graphic. DB gain from paralleling those drivers is reflected in the System curve.

View attachment 2528555

Pending actual, verifiable sensitivity performance of the midrange drivers, this could be a place to start for further refinement. It's about the limit of my experience level. There are vastly more knowledgeable members capable of devising a more elegant solution.
Wow, you did an awesome job. I really appreciate the amount of effort here. I'll try that in person when I can and show you. Thanks alot!
 
Here's a view of individual curves. Note that only one midrange and one tweeter are shown. Try to show their twins and the curves just overlay exactly, with no change to the graphic. DB gain from paralleling those drivers is reflected in the System curve.

View attachment 2528555

Pending actual, verifiable sensitivity performance of the midrange drivers, this could be a place to start for further refinement. It's about the limit of my experience level. There are vastly more knowledgeable members capable of devising a more elegant solution.
I am wondering how mine(how ever slightly) is different then yours? Thanks again, just ordered the parts.
TM xover 4 pro.PNG
Also, thanks for pointing out the mid-range mistake. The program I had used is very new to me and I forgot to change the minimum y axis value to 50 instead of 0:
45 mistake.PNG
 
Last edited:
I am wondering how mine(how ever slightly) is different then yours?
Amazing that worked out so well. Never though to try inverting tweeter polarity. Difference is indeed slight.
Also, thanks for pointing out the mid-range mistake. The program I had used is very new to me and I forgot to change the minimum y axis value to 50 instead of 0:
Had read about FPGraphTracer but not yet tried it. Your example shows it does a great job of creating data from an image. Got it downloaded now.
 
Got the files, Thanks!
Had to pause for an anniversary celebration yesterday (seems to happen every year ...). Got to play this afternoon though. Kept struggling to get the midrange level up. Viewing the bare driver in XSim using the .frd file shows average SPL below 80dB and an 85dB peak at about 450Hz:

View attachment 2528461

Published literature shows the same curve, but 10dB higher:

View attachment 2528463

Adjusted sensitivity up 10dB in XSim to reflect published specs and it behaves much better with the other drivers.

View attachment 2528485

Tweaked things a bit and got a reasonable system response curve ...

View attachment 2528488

... with this circuit:

View attachment 2528492

System impedance here never dips below 6Ω. Had wrestled with low impedance issues in earlier attempts.
Part of the challenge (for me) is a tweeter that plays down to ~ 1500Hz and a woofer that works up to the same -- they seem content as a 2-way system. That prompted 2nd order filters for tweeters and woofer to make space in the middle for the Goldwoods, which are connected inverse phase.
Hello. Why in a 3 way system you would run a tweeter that low? I think you could play those mids a couple of octaves higher, even a 1st order low pass filter, and use the tweeter from 3 or 4 KHz.

Looking at your individual drivers response, I see you are using the mid just to play a "peak" at 1800Hz.
 
Hello. Why in a 3 way system you would run a tweeter that low? I think you could play those mids a couple of octaves higher, even a 1st order low pass filter, and use the tweeter from 3 or 4 KHz.

Looking at your individual drivers response, I see you are using the mid just to play a "peak" at 1800Hz.

Both the woofer and tweeter have remarkably wide range. The DS315-8 woofer claims frequency response out to 2500Hz. Though that's a tad optimistic.

DS315-8 response.jpg

And the DC28FT-8 tweeter, with a low 834Hz resonant frequency, claims usable range from 1300Hz to 20kHz. It's advertised as "Recommended for crossover points as low as 1800 Hz!"

The two could be used together to make a workable 2-way system. But this is a 3-way with midrange that needs something to do. So rather than beat down the woofer response with a big inductor, why not let it do as much as it can do well, then kick in the mids to take over where the woofer starts going polar before passing off to a safe range for the tweeters.

The idea is somewhat inspired by similar circumstance in the VL Nova 8B Crossover Mod. It too has a wide response range woofer and very wide range tweeter. The twin mids fill in barely an octave between them.

VL 8B_5B_cross.jpg

There are no doubt other choices that can be made here. This is just one among them.
 
Both the woofer and tweeter have remarkably wide range. The DS315-8 woofer claims frequency response out to 2500Hz. Though that's a tad optimistic.

View attachment 2529835

And the DC28FT-8 tweeter, with a low 834Hz resonant frequency, claims usable range from 1300Hz to 20kHz. It's advertised as "Recommended for crossover points as low as 1800 Hz!"

The two could be used together to make a workable 2-way system. But this is a 3-way with midrange that needs something to do. So rather than beat down the woofer response with a big inductor, why not let it do as much as it can do well, then kick in the mids to take over where the woofer starts going polar before passing off to a safe range for the tweeters.

The idea is somewhat inspired by similar circumstance in the VL Nova 8B Crossover Mod. It too has a wide response range woofer and very wide range tweeter. The twin mids fill in barely an octave between them.

View attachment 2529837

There are no doubt other choices that can be made here. This is just one among them.
Amazing that worked out so well. Never though to try inverting tweeter polarity. Difference is indeed slight.

Had read about FPGraphTracer but not yet tried it. Your example shows it does a great job of creating data from an image. Got it downloaded now.
Thank yall for helping me out. I recently started to go down a long and confusing path known as diy speakers, and yall gave me the directions. I ended up using the design that Stuart made for it was the best sounding, plus I did a few mods of my own.
Thanks everyone!
 
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