[roymail]

I have a pair of Klipsch 2-way monitors that sound pretty good, but I think they can do better with improved crossovers.

The stock crossovers appear to be using some electrolytics, mylars, and cheap coils and resistors with 2nd order to the woofer and 3rd order to the tweeter.

How much improvement can I expect by rebuilding them using the same configuration but substituting better parts like Sonicaps, Erse, Mills, etc?

I would not do this except the speakers appear to have real promise.  I'm also thinking about rebuilding the cabinets.

Thanks for any advice.

[Æ]

I have a pair of Klipsch 2-way monitors that sound pretty good, but I think they can do better with improved crossovers.

The stock crossovers appear to be using some electrolytics, mylars, and cheap coils and resistors with 2nd order to the woofer and 3rd order to the tweeter.

How much improvement can I expect by rebuilding them using the same configuration but substituting better parts like Sonicaps, Erse, Mills, etc?

I would not do this except the speakers appear to have real promise.  I'm also thinking about rebuilding the cabinets.

Thanks for any advice.

There will definitely be an improvement, how much though is hard to guess.
Do the upgrade and let us know.

One word of caution. You might upset the original levels between the woofer and tweeter. Be prepared to tweak the tweeter attenuation if necessary. You may need a bit more or a bit less depending on the outcome.

Cheap crossover inductors are sometimes chosen, simply because they are lossy. KLIPSCH may have "tuned" the woofers, deliberately adjusted the weight of the bass by using cheap inductors.

You can always reinforce and/or damp the original factory enclosure instead of building new ones.

[cujobob]

You'll get an increase in resolution for sure, I'd start with no rez in the cabinets for damping and maybe use sonicaps or jantzens. Use a decent quality bypass for the tweeter, too. As for the coils, I'd check the layout first and probably wouldn't mess with anything but positioning just to be safe. Inductors don't seem to show as much improvement when upgraded.

[roymail]

Appreciate the advice so far. 

[Æ]

You'll get an increase in resolution for sure, I'd start with no rez in the cabinets for damping and maybe use sonicaps or jantzens. Use a decent quality bypass for the tweeter, too. As for the coils, I'd check the layout first and probably wouldn't mess with anything but positioning just to be safe. Inductors don't seem to show as much improvement when upgraded.

I visited a friend the other day who is rebuilding a VELODYNE subwoofer. The amp is dead and the woofer is blown. The enclosure looks nice from the outside, but inside there was no cross bracing, so he added some. Exactly cut lengths of 7/8 inch hard wood dowel inside from each wall straight across to the opposite wall.

[Big Red Machine]

motorcityM3 tried upgrading some Klipsch speakers and ended up with new speakers instead.  Cost him money he could have put toward new.

[cujobob]

motorcityM3 tried upgrading some Klipsch speakers and ended up with new speakers instead.  Cost him money he could have put toward new.

This is ultimately the great risk. Some upgrades can be pretty cheap, though.

[roymail]

motorcityM3 tried upgrading some Klipsch speakers and ended up with new speakers instead.  Cost him money he could have put toward new.

You're right, I'll probably start by either reinforcing the cabs or building some new ones which I enjoy doing anyway.

Bypassing and replacing some caps won't be that much of an investment.  I like doing this sort of thing, but many of you guys know much more than I do about doing it.  Appreciate the ideas and advice.

[smata67]

Done this many times to older classics.  The coils and resistors are fine.  It's the caps you want to experiment with.  Always, same values of uf and same or higher voltage.  You can sub the lower value ones by Dayton polypropylene caps.  I also get electrolytics of the same value (they are pennies, be sure they are "bi-polar") and bypass with a .022 film/foil, sometimes this sounds better.  For higher value caps, a combination of electrolytic and polypropylene, whatever is within your budget.  I usually don't spend more than $10 or so on replacement caps for both sides.  I like to solder slip on connections and replace woofer wiring with higher gage speaker wiring.  Reinforcing cabinets is always a good idea.  Expensive "boutique" type capacitors are a waste of money, especially on lower grade speaks.  Have fun.

[roymail]

Done this many times to older classics.  The coils and resistors are fine.  It's the caps you want to experiment with.  Always, same values of uf and same or higher voltage.  You can sub the lower value ones by Dayton polypropylene caps.  I also get electrolytics of the same value (they are pennies, be sure they are "bi-polar") and bypass with a .022 film/foil, sometimes this sounds better.  For higher value caps, a combination of electrolytic and polypropylene, whatever is within your budget.  I usually don't spend more than $10 or so on replacement caps for both sides.  I like to solder slip on connections and replace woofer wiring with higher gage speaker wiring.  Reinforcing cabinets is always a good idea.  Expensive "boutique" type capacitors are a waste of money, especially on lower grade speaks.  Have fun.

smata67,  thanks for sharing your experience and for all the good suggestions and helpful information.  Really appreciated.

[Æ]

Done this many times to older classics.  The coils and resistors are fine.  It's the caps you want to experiment with.  Always, same values of uf and same or higher voltage.  You can sub the lower value ones by Dayton polypropylene caps.  I also get electrolytics of the same value (they are pennies, be sure they are "bi-polar") and bypass with a .022 film/foil, sometimes this sounds better.  For higher value caps, a combination of electrolytic and polypropylene, whatever is within your budget.  I usually don't spend more than $10 or so on replacement caps for both sides.  I like to solder slip on connections and replace woofer wiring with higher gage speaker wiring.  Reinforcing cabinets is always a good idea.  Expensive "boutique" type capacitors are a waste of money, especially on lower grade speaks.  Have fun.

Make sure the caps are Non Polarized (NP). Bipolar=Manic depressive.

[jerryleefish]

I build my crossovers in order to use better quality components, choose cross
over frequencies as well as, match speaker impedances. You can do it all yourself but it is a project. Literature describing circuits,and showing tables for component values is a must. Winding coils can be diy or possibly you can purchase them. Solid copper coated wire 1/16th diameter required and a device to measure inductance would be needed Quality capacitors (poly prop.)provide the greatest improvement. Use quality resistors if called for. Potentiometers should not be used if possible.
Speaker manufacturer's crossover are usually of poor quality and should be replaced. Complete crossovers are available if can match the crossover frequencies.