Just wanted to say thanks for all the help!
DIY Audio was definitely one of the more challenging ventures I’ve taken on but I’m finally starting to hear the fruits of my labor!
It’s still a work in progress but I’ll post pics in the home theatre section of how it’s all turning out.
For anyone in the future that runs into the same questions I did here are my conclusions:
- Use Passive Crossover Designer and trust the process. PERIOD. I did find some minor errors, but even when I fixed them I noticed that although the numbers between PCD and Xsim did not match completely, the shape of the curve was the same so it all worked out just fine.
- In regards to baffle and box sizes I watched a ton more videos on it, the most important part was realizing that this is mostly focused on the woofer and the tweeter choice is essentially irrelevant- thus I was able to the original ESO 5/7 plans as written. I also modified the dimensions of 2 speakers as needed to fit my design, they needed to be thinner to fit in their cavities, BUT I was increased the overall baffle size to compensate and they sound great.