It sounds like the Super 3 HO tower will more or less 40 liters after we reduce the volume of internal bracing. That's not that far off from the volume (per driver) of the Super 3U or Super 3 XRS, which strikes me as what has apparently settled out as the "optimum" volume for the RS5.
I re-read some old posts and noted that the original 1.5 way monitor was low passed at 300hz. I think you are onto something in that the main driver will dictate the helper woofer crossover point. With the rising response of single drivers, we would expect to need low frequency assistance at a higher frequency with a 4.5" driver than a 6.5" one. As I have noted in another post, typical 4.5" drivers of reasonable efficiency will begin rolling off at 1-2 dbB/octave below 1khz. Your practice of bringing a second one at 6dB/octave at 500hz would appear to perfectly balance that rolloff.
500hz also is typically cited as the point of equal power distribution, require 50% of amplifier power below this frequency and 50% above. This, combined with the RS5 FR being 3dB down below 1khz strongly implies the "need" for twice the efficiency below 500hz. The 1.5 way configuration appears to simple add twice the surface area (and twice the efficiency) below this point in a seemingly innocuous way.
We still can't escape the realities of physics, and the deepest bass - if it is important to us - may still require supplementation below 50 hz or so. That being said, we would no longer need to extend this bass reinforcement into the mid or upper bass.
I'm not 100% convinced that 16 ohm speakers are necessary. When paralleling driver below 200-500hz only, it does not appear that we are actually creating 4 ohm speaker. Speaker impedance is nominal at best, and in the case of full range drivers we generally expect to see a rising impedance both at high and low frequencies. The 500hz inductor applies a higher impedance at the lowest impedance region of 500-1,000 hz. I would expect the region of 100-700 hz to be about 6 ohms or so, with frequencies both above and below presenting a higher impedance of 8-12 ohms. I think that this nominal 6 ohm impedance is ideal for the Decware 6 ohm output transformer. Other amps may be happier with higher impedances however. The EL84 of the Decware Super Zen has a 8khz primary, which gives a very good turns ratio into 6 ohms. Other amps, especially DHT amps, may prefer to see a higher impedance load. The 2.5k primary of a 2A3 comes to mind.