Interesting project Brad. I can understand manufacturers of speakers must spend thousands of hours tuning various drivers and crossovers, playing with cabinet construction ect.
I think all speakers have a target sound, the designer perceives as his ideal. Then costs factored in of course.
I have built a few DIY DACs and tried various capacitors from different manufacturers. It really affected the sound,particularly on the coupling position, and even on the PS regulation positions.
I am playing with my Zingali crossovers at the moment. Not anything as radical as your project, rather a tweaking exercise, trying to wring a bit more out of them. Speakers are hugely affected by room acoustics as we know. If a designer has them zero'd in a mock home setting in the factory, how do we know they will sound the same in our own room? I guess we don't.
So my thoughts on tweaking the sound, is play with different caps on the passive crossover, and then finally look at the attenuation of the 2 drivers in my setting. I get the feeling the horn is attenuated a bit too much. My (work based) music room is smaller than my demo room, and is getting more loaded with bass because of that.
I will rebuild the caps first, then after some weeks of burn in, look at different attenuation on the horn, maybe reduce it a bit. It is on 10 ohms at the moment, I may try half that, see what that sounds like.
This subject is interesting. It is not something I see talked about much, more leave the speakers as they were designed kind of approach. That is true, but there is always room for improvements, even if just upgrading the caps. Caps tend to be ok in mid priced speakers, but not the best.
I am trying the better Mundorfs. I couldn't get Duelunds in the values I needed, only the VSF types, and they are crazy money.
Back to Brad's project, sorry I digressed a bit. I don't think me little project needs a separate thread.