Well,
I ain't sure when Dennis made the remark about the significance of the roundover, but Dennis and I a/b auditioned the 1801b and 1801bf 2 weeks ago. Neither of us could hear any difference in the midrange.
On a 9" wide flat baffle there is a measurable ripple on axis with the tweeter using a gated time response and square baffle edges. This disappears with an in-room sweep. It also varies when off-axis. I have found very neglegable ripple with the narrower 1801f baffle - even with a gated time response.
The gated time response is essentially an anechoic response, and the sweep is an in-room response.
Even when using a 9" wide square cornered baffle, there is no audible impact at my ears.
Given the example of $20k+ speakers, some use a rounded baffle edges, and some do not. I believe this exemplifies the theory, measurement and science regarding this matter. While there is some measurable impact with drivers mounted in the center with square corners, the impact really isn't so audible. Some guys might claim to hear something, but would likely not pass an a/b test.
Insofar as the thicker/thinner cabinet walls, I really don't know. This is one of the things I need to resolve before formal bennediction of the 1801f.
However, a thicker back wall won't hurt anything.
Dave