"1. The decision to use a MT driver design vs. a MTM three driver design. Is it simply to balance speaker size & cost over diminishing performance benefits (in my limited understanding) of the MTM? At this sota design level, I see numerous examples of each and wonder why I see no apparent consensus. I'm thinking of the Song Towers, top models of Wilsons, Hansen, Eggleston, YG Acoustics, Magico, Evolution Acoustics (MTMs) vs. (TM) Usher BE, smaller Wilsons, Magico, YG Acoustics, Kharma, etc."
This really wasn't a close call. One of the main advantages of an MTM configuration is added sensitivity overall and power handling in the bass. But that only holds for a 2-way. In a 3-way with one large woofer capable of plumbing the depths down to 19 Hz, the woofer sensitivity will establish the system sensitivity, and it will be quite low if the woofer can really deliver the bass goods (remember the Iron Law of bass). So the added midrange senstitivity of an MTM would be completely wasted. You would have to pad down the mids anyhow. And the Accuton doesn't have to produce any low bass, so power handling isn't an issue either.
"2. Midrange driver size. The Accuton ~3"+/-4" diameter midrange. Wow, that seems like a small diameter. I understand the desirable benefits of speed and dispersion with smaller driver sizes, but how is the gap between the midranges lower end of ~300 Hz down to the woofer get filled? There is obviously some juggling of sizes (maybe a 5"-6" midranges) with frequency ranges taking place."
The Fs (natural bass resonance)of the Accuton is 96 Hz. It's crossed to the woofer at 350 Hz, so there is no hole in the response to fill. The Accuton and the Big Hog woof blend together perfectly using 2nd order acoustic slopes. And by the time the Accuton hits its Fs, it's 24 dB down. If it were used in a small 2-way, it could produce substantial output at 96 Hz. The HT4 design doesn't call on it to produce much of anything there.
In retrospect, I wish I had thought of the Accuton in the first place. I had a pair lying around from a previous experiment that didn't work out due to a tweeter with no low end output, and I forgot all about them. When the FAL driver proved unworkable because of a design defect the factory couldn't fix, the light bulb finally clicked on.