Acceptable manufacturing variation in response - your opinion

Is all this noise before the impulse normal?
 

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I'd expect pretty much +/- 0.2dB accuracy between identical measurement sweeps. Even closer.

First we need to remove the noise from your sweeps. Are you measuring in a quiet location? (any background HVAC or other racket?)

Your gate markers are hard to see. What is your environment? In a typical 8' room - putting the DUT midway between floor / ceiling - you're looking at a gate of around 4msec (i.e. 1000/4 = no lower than 250Hz resolution).

Can we see your impulse window in % Y scale - with horizontal range of -0.5 to 8 msec?
I am in my shop. There is a yoga studio above me and they are very noisy an annoying. I can come back later tonight when it is quieter
I have 14 foot ceilings and its very big. Probably 50' accross and 50' to the back wall
 
I think it was this timing and cal reference that screwed it up. I changed it just timing reference and now it is working fine.
 

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1) Your SPL is probably not calibrated correctly which is fine, as it doesn't really matter. But it may help you think through things when you get to your xo work to have it reasonably accurate. If you don't have an SPL meter, download one as a phone app and calibrate the SPL in REW just to keep things close. This will also avoid questions about SPL levels when you aren't really measuring at 129db.

2) Earlier it looked like you were getting reflections in your measurements, although that may be gone with your new delay settings. But...What is your speaker stand and mic stand like? If you have sharp surfaces then you may be getting reflections. If so, you can put some padding/foam on those surfaces. Here is an interesting test by Troels.

3) I try to follow the VituixCAD directions for REW EXACTLY. I know little differences may not matter much, but I'm not as experienced as most of these guys so I don't want to leave anything to chance. Here is a screenshot from the Vituix instructions. I don't know what difference it makes to have the Length 1M instead of 512k, but Kimmo has 1M so I use 1M. (I don't measure tweeters down to 5hz though.) I do notice that he has "Use loopback as cal and timing refernce" set, so that makes me wonder about your issues above. The instructions do have some REW setup steps on pages 3 and 4.

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Your level is very high for a normal frequency response measurement. 86 dB or 2.83 V input is more typical.

As discussed in the other thread, if the background noise is 30 dB below your signal, the influence to the measurement will be trivial. Did you take a measurement of the background noise to see how bad it really is during the day?
Sometimes it is pretty loud when they walk and then REW will say "distortion is too high". So it reads their footsteps as distortion at lower frequencies.

I have not set the SPL level. I'm really taking measurements at about 60 db
 
1) Your SPL is probably not calibrated correctly which is fine, as it doesn't really matter. But it may help you think through things when you get to your xo work to have it reasonably accurate. If you don't have an SPL meter, download one as a phone app and calibrate the SPL in REW just to keep things close. This will also avoid questions about SPL levels when you aren't really measuring at 129db.

2) Earlier it looked like you were getting reflections in your measurements, although that may be gone with your new delay settings. But...What is your speaker stand and mic stand like? If you have sharp surfaces then you may be getting reflections. If so, you can put some padding/foam on those surfaces. Here is an interesting test by Troels.

3) I try to follow the VituixCAD directions for REW EXACTLY. I know little differences may not matter much, but I'm not as experienced as most of these guys so I don't want to leave anything to chance. Here is a screenshot from the Vituix instructions. I don't know what difference it makes to have the Length 1M instead of 512k, but Kimmo has 1M so I use 1M. (I don't measure tweeters down to 5hz though.) I do notice that he has "Use loopback as cal and timing refernce" set, so that makes me wonder about your issues above. The instructions do have some REW setup steps on pages 3 and 4.

View attachment 1334983
Yeah I didn't bother with calibrating the SPL as it doesn't really matter for my purposes. Yes, it would stop people from commenting about it though. I do have an spl tool on my phone. It is type c rated and is accurate to within 2 db.

It's that timing a reference and cal that cussed the issue. If I set it to just timing allllllll the problems go away
 
Sometimes it is pretty loud when they walk and then REW will say "distortion is too high". So it reads their footsteps as distortion at lower frequencies.

I have not set the SPL level. I'm really taking measurements at about 60 db
If you take measurements in the 86db range, all of that background noise - which has not increased my 26db - will be 26db down RELATIVE to your new measurement.
 
I don't REW so I'll let someone else answer the microphone gain part, but without at least a ballpark idea of actual SPL for the signal and noise there's no realistic way to answer whether your sweeps need to be louder to improve accuracy.
 
I was able to properly take all the measurements now. With the SPL calibrated.
Thanks everyone for your help

Honestly, this was a very frustrating learning experience for me but I've got it now. Luckily I only have to learn things once.
 

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So I need to be playing these sweeps much louder then? When I go louder then REW says it's clipping. So do I turn the mic gain down to play the sweep louder?
Sweeps normally are unpleasantly loud from 1kHz up. Measure amp output with a decent AC coupled (true RMS in the right ranges) Voltmeter; you should have a reading between 2 and 3V, ideally 2,83V.