TPA3251d2

can you de-rate the coils current capabilities if you are using four rather than a single coil that can handle 10-15A @10uh or 7uh ?

Correct.

If using just 2 coils in PBTL, they need to do 1.4x times the current for the same wattage in 2R compared to BTL 4R.

As you double the output power due to PBTL 2R capability, the inductors needs to be rated 2x times the current handly than 4R BTL when pushing.

If using 4 inductors, no re-rating is needed.
 
So your saying as long as I keep the impedance up above 4 ohms and I could use an 8 ohm voicecoil that bridged mode would be the better choice. The amp will never see a 2 ohm load so I don't have to plan for that. I get to specify the voicecoil impedance so can ideally pick anything I want within reason.
 
Function of the LC filter is not to make a TI chip stable, function remains reducing, controlling EMI. Air cores are said to disfunction there. But standing toroids disfunction too, according to Hypex :)

I guess EMI standards and cost are the main issues for commercial designers but diyers are more concerned about placing coils too close (mutual inductance) or emi induced noise. I reckon that simply fitting alternate coils above/below the pcb would mitigate this enough to be a non-issue, and if not, some deflective shielding, so the biggest issue is sourcing or making the coils and then testing them to avoid the psychology of "It sounds better cos I made it".

Worth having a look at 10 year old discussions about air cores and mitigating RF using ERS paper:
http://www.diyaudio.com/forums/class-d/95740-shielding-charlize.html?perpage=25&pagenumber=2
 
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Indeed - results! But things are progressing slowly - haven't even persuaded my other half I need two new 250VA toroids for the (shh... two) new amp(s). When that does happen, or if, the next thing is to hook up the scope to the 10K:10K trafo and see what's happening with input/output voltages across the audio band.
 
An idea occurred to me - you could present this to her as 'I'm thinking of DIYing my transformers, I just need this (expensive,bulky) toroidal winding machine and some cores and wire. Or do you think its easier to just buy the finished product?'

I like the thinking, kind of a bait and switch... this hobby is so challenging. ;-) I reckon new duvets and Hello Kitty covers will probably be the kind of Faustian deal I'm forced into.