mjosef:
We had a problem with crackling panels for several days. Since the five are in series to present a 15 Ohm load to our OTL amps, one bad panel made them all sound bad.
We finally localized the problem to a rear panel but could not immediately find the defect, so we replaced it temporarily with a 4 Ohm resistor.
As it turned out, a new batch of ring terminals--an integral part of the rebuild we do on every panel--had about 1/10mm more meat on it and was causing an intermittent short with adjoining traces. Filing down the terminal and reseating it solved the problem. Just another typical snafu under show conditions. My thanks to Dave Housteau's keen eyesight and precision trim work.
As for that "cobbled together" look, you have no idea! We were literally carving away at those thick baffles (3" front, 2" back) with hammer and chisel during prototyping. We eventually covered our crude recuts with masks but truly, the show speakers were an ongoing experiment, now complete.