8 Excel W12CY001 looking for a DIY project to fit in

I think I am going with somewhat smaller box, if there are no objections🙂
 

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Vb 6.3L (tuned @ 50Hz) with lining on the wall: the brown line is the response including the baffle step loss according to your baffle size. Vent size is 4x20cm. You can use an L-shaped pvc pipe.

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The light yellow line is the turbulence warning for your vent.
 
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ZDR, I thought you are doing MTM? That would make more sense to me, personally I don't like 2.5 way unless you are using linear phase dsp filters.

Nice metric with the port air velocity! 👌 Is that for 2 woofers? I'm wondering if anyone knows how the limit of 17m/s was derived?

One thing I would point out (OTT for this thread really) is velocity is not turbulence. Changes in velocity between parallel air streams cause turbulence. What we really want to know is the Turbulence Kinematic Energy TKE. In CFD sims I've seen cases of lower average and max. velocity, yet higher TKE when adjusting port geometry.
 
Oh no, that's a bad idea 😵

Sink 'rebate' all drivers. Your woofers already have a flat side, so use those to get the woofers close to the tweeter. Use the waveguide I shared to also give you a flat edge for the tweeter to join the woofers. The waveguide will also make the time alignment of the tweeter and woofers correct so the crossover will be easier.

Cut the rectangle for the tweeter waveguide. Then cut the circle for the woofers. (EDIT: I just realised of course the bottom of the woofers is also flat so my drawing is not exactly right.

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