Finally an update....part 1:
I decided to cut new patch panels made out of plywood spraypainted black, and mount the crossovers and L pads to the interior side of those. It went really well, and I thoroughly enjoyed it. I'd replaced a few caps and a resistor before, but never built a crossover. It was definitely an unexpected challenge learning to apply a crossover schematic to real life....but I get it now, and expect it to be like riding a bike from here on out.
Since only 2 woofers match, I decided I would make one pair with the best of all parts. Two matching woofers, two tweeters with straight phase plugs, and the best looking lenses....and since I did it this way, I also took two of the spring terminals from the other pair to use as exterior terminals for the 2440's wires to go into the cabinet to the crossovers. (see pics if that doesn't seem to make sense) I wanted it all to match, at least on this pair.
All went relatively well. Challenges to solve and hurdles to jump over, of course, but, it's done and I learned a lot and had a great time doing it.
Pictures of, in this order, a tweeter with new weatherstripping seal, one of my work spaces (the other was the living room floor), the finished crossover, and one of the speakers.
HOWEVER........
I now know why the tweeters weren't in use. They need work. One or two have barely any output above like 12khz I think it was, another has no output above about 15khz (and drops off severely after 10-12khz), and the other I haven't tested yet but it sounded to be doing the most out of the whole bunch, and yet still not much. There wasn't much sound coming out of it, and I didn't feel that it really added much to the entire picture. Sooo, maybe diaphragms?
But here's the thing. Do I want to invest that much money in these? Because yes, they do sound good with just the mids and woofers going. Surprisingly good. I sat and smiled while listening, but the bass is not my cup of tea. I think I'm learning that I prefer sealed cabinets. They have nice powerful bass, but like other ported speakers I've heard, it's open and kind of hollow-ish. There is definitely a tightness to it...I'd say tighter than any other ported speakers I'd heard prior....but not tight enough. It's good, but leaves me wanting, even with the house rattling.
Then there's the midrange. It sounds good, and had me smiling, but it sounds like it's coming from far away. That's the best way I can put it. But in my research I saw someone say they had the same experience with big lenses in home settings, and that they lacked the immediacy he likes - and that when he took the lenses off, it was solved. So, I should try that.
And that was my plan....until this happened. (part two coming immediately after I finish this - I hit my limit on pictures in this post)