Also, don't avoid hornresponse. It is a major timesaver and sanity check and not too difficult after you get past the user interface (there are pretty easy to follow directions in my spreadsheet's pdf instruction for hr). There are a lot more arrangements and mid driver choices that DON'T work well than those that do.
Yes, to increase the high frequency corner frequency, the air volume in front of the the cone must be minimized, while still allowing for full driver excursion without hitting the plug.Weltersys,
If I could fashion a concave shape out of foam that sits inside of the surround (does not interfere) and decreases the volume even more, I can get more high end to the MF?
Foam is generally porous, the plug should be as hard as possible. You could make plugs from Bondo Hair using the cone (covered with cling wrap) as a mold.
Making the ports larger increases the HF band pass frequency, but has the unintended consequence of messing up the HF driver's response if too large.would changing the port size (as in larger) have the same effect or am i thinking about this basackwards?
Your 5" drivers will probably hit their lower excursion limits well before your Dayton D250 at 1200 Hz, going with smaller mid drivers will reduce mid output.Thanks Weltersys for all of your assistance. Back to shop and I am seriously considering a smaller driver then the 5" I am currently experimenting with. Next iteration; minimize the area between cone and horn.
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