I got some more work done over this weekend. When I built my X-LS Encores I didn't do any upgrades including No-Rez. I used thick floor tiles for dampening, and fiberglass insulation. I figured it didn't make much sense to use No-Rez for the center only. However, I am going to upgrade the cross overs for both the X-LS Encores, and The X-CS Encores.
So.. I decided to again use the thick floor tiles in this quite complex X-CS speaker box.
My idea to use splines to align everything has so far worked great.
My original splines were too loose a fit, and the grain orientation was not very strong, so I ripped some strips (splines) from 3MM Baltic Birch plywood, but they were a bit tight. I ran them through my planer and got a nice fit.
My decision to use the floor tiles presented the same problem using No-Rez, too many things in the way, requiring a lot of cuts/fits. Because I had cut all my spline grooves for the top and bottom at the same time which worked great! I decided to try applying the floor tiles to all surfaces before gluing the cabinets together.
This method took a bit of thinking/measuring, but so far has worked out very well. I don't have to try and fit all the pieces into tight spaces. I used contact cement to glue the tiles, so working on flat panels was much easier.
I now have to decide what to use for the foam layer. being a non ported enclosure, I am no sure what is the best choice.
My X-LS Encores:http://www.audiocircle.com/index.php?topic=108371.140