Well, I spent about 4 hours testing and on/off the phone with Danny. I did find one wiring mistake in the tweeter network, but fixed that and the FR is still way way off. The tweeter rolls off way too fast and too early, and the midrange looks like a 1st order rolloff starting around 500hz. The result is a suckout from 2-3000hz, and tweeter level that's 4-5db too high.
I'm too tired to upload a new picture, but Danny and I are both totally stumped. Both speakers measure almost exactly the same, both just as wrong. I've went over the tweeter and midrange network 100 times and don't see any mistakes.
... talk about frustrating!