Roll off safety in terms of Xmax and SPL reference for home audio 3 way

It was for trying to match THX reference level peaks as these are apparently 105dB at the listening position, with dB loss over distance and the speakers being a couple meters away it would have to produce 115dB ish at 1m. Which does sound very extreme

That's how I like to design - for that reason. Woofers sometimes 5-10dB higher, to account for baffle step and house curve (bass shelf).

But yeah... pro drivers is normally where it's at if you put the bar that high...

Quick simulation of the CAW 938 show's you should be alright as long as you cross to subs (on the high side) and have a powerful amp.

This is in 50L sealed, 800W peak, electric LR4 HP @ 100Hz (and LWT to flatten the response to Qts 0.707 before applying LR4, for true acoustic LR4). As you can see, SPL 115dB in the passband and Xmax at 100Hz.

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The CAW 538 isn't perhaps the ideal filler driver between the CAW 938 and ET 338 but can certainly do it. Here it is 6L sealed, 1,000W peak, electric LR2 HP @ 200Hz (and LWT to flatten the response to Qts 0.707 before applying LR2, for true acoustic LR2). Again, SPL 115dB in the passband, and Xmax at Fc 200Hz.

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This of course if you want to spec for SPL 115dB peak at listening position (less actually since no baffle step). And without knowing your drivers' power compression and distortion profile at these power levels. But point is you'll probably be alright as long as you protect the drivers and give them some power when you want them to go loud ever so often. In real life, you would probably be OK to cross to subs at the standard 80Hz, if that's a fixed frequency available to you (through sub or HT receiver etc).

If I were you, I'd consider getting a miniDSP Flex and a measurement mic (to go with REW) to make life a whole lot easier.

Could also sell the CAW 938 and get a beefier woofer (e.g. SBA Nero-15mwn700d) if you want more full-range. Or if you get a bigger woofer, replace the ET338 & CAW 538 with a 1" compression driver and a horn of similar width (222mm) to go with the CAW 938 as you mid.
 
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Most musical peaks above 100Hz are short enough (<10ms) - but could always set a limiter at 10ms if worried.

1000W peaks on 20dB crests at 115dB means 10W on average SPL 95dB. Most popular music is less than 15dB crests though, which is then like 300W peak.
 
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