replacing film caps in crossover with lower rated (voltage) ones?

No problem. poly caps are often 250V because in some cases it is cheaper to get higher rated caps than lower, since the higher rated ones are produced in higher quantities.


And for science, to push beyond 100 V AC then you would need to push a lot of power through that crossover. If we are generous and assume that the cap rating is DC so we divide 100 V by 1.41 and calculate max power given a nominal resistance then we get:

4 Ω: 1200 W
8 Ω: 600 W
16 Ω: 300 W

Even the inefficient speakers are usually at least 87 dB / w @ 1m. 200 W would net 110 dB, which is a lot. I think you will be fine 🙂