Hi,
I'm new to this forum. Thanks for posting the pictures! I seem to have the exact same model & build as yours (it looks the same inside, which is not necessarily true for all Minimus 7's, as I understand). Just got them from eBay last week after hearing them at my friends house. They sound pretty good with some music (e.g. what was playing at my friend's house at the moment) but generally not great, so I read up a little bit and decided to try to put in a real crossover.
Is there a reason the original inductor is air-core? I noticed that one of yours is, also (but you're not reusing the original one). Ferrite or permalloy would be more compact but possibly would introduce some distortion. I found some ferrite-core inductors on DigiKey I was going to use, but now I'm having second thoughts. The parts I found are rated for 1.6 A (390 uH, and I can just reuse the original part, I guess) and 2.5 A (1 mH, ferrite, toroidal). In this circuit, they should be more or less OK at max power for which these speakers are rated, which I don't intend to supply, anyway. The saturation current is not specified, so I assume the rated current determined by the wire gauge. These are general-purpose inductors, not advertised as super linear or "audio grade", although generally I'm pretty skeptical about magical audiophile parts. The inductor from Parts Express is pretty big and all they say is that it's "high grade" (I assume permalloy or something similar) and can "easily handle 250 Watts of power", which is basically illiterate. Which is not to say that that isn't a great part. Can anyone comment on this?
Aslo, would it make sense to try to add more filling? As far as I understand, this would increase the effective volume of the enclosure and thus lower the resonance at the cost of sensitivity, which would be fine by me. Has anyone tried this? Would it actually extend the bass response, and what other effects might it have besides lowering sensitivity?
And, finally, I noticed that the woofer is rated for "nominal 5 W / music 10 W max", while the speaker is rated for 40 W max. Has anyone else noticed this?
Thanks,
Sergei