So I screwed off the K77 drivers to have a look at the gaskets. They were rock hard but still in tact, so I figured I'd replace them. I had some of this foamy rubber sheet material sitting around from some long-ago kid project, so I cut some new ones.
I noticed that the hole on the stock gasket was smaller than the opening on the driver, so I cut the opening a little larger. When I put them back together I noticed that the throat diameter of the horn was matched to the gasket and not driver, hence the small opening. I'll probably go to the auto parts store today to get some gasket material and remake them to the original dimensions.
I also had the chance to do some REW testing. Here are the frequency responses of the Right (red) and Left (green) Khorn compared to a Cornwall (blue). All tested at 92db @ 1kHz @ 1m.
Overall you can see that the Khorns are much smoother from top to bottom. They don't have the exaggerated bass of the Cornwalls. Comparing total harmonic distortion:
As expected, the Khorns have quite a bit less distortion than the Cornwall. Everywhere except for the trebles, where the Khorns have a nasty spike in distortion from 5-8kHz. Looking at the different distortion components from a single Khorn sweep:
Red is noise floor. Blue is 2nd harmonic distortion and yellow is 3rd harmonic distortion. I think that jump in 3rd harmonic distortion above 5kHz explains the hard/shrill tone I'm hearing. Looks like I do need a set of Dave's SMAHL's. Going to order today.