Where to cross? There are several schools of thought on this. Let's look at 3.
1) Cross low. This is the intuitive school of thought. "I have this great fullrange driver, let's use as much of its range as possible." The idea is that the FR driver just needs a little help on the bottom end, so we cross low. Maybe below 100Hz.
This way most of the audio range is covered by a single driver. The woofer only fills in the lowest ~2 octaves where SQ is less important - and there is no x-over in the critical midrange. Makes sense.
2) Cross higher. This is the "Why burden the FR driver with bass?" school. That's what your woofer is for. A good example was listening to Nelson Pass' very nice OB system at the recent RMAF. I was seated right next to Lynn Olson who was dismayed that Nelson had crossed the Lowther FR drivers so low to the 2x10" woofers. About 80Hz, IIRC. The problem there (for me) was Doppler. At 80-250Hz the Lowthers on OB will move quite a bit. That movement will modulate the higher frequencies. Not hard to hear the effect. A driver in a box will not move as much, so you won't notice the Doppler so much. (Except for very small FR drivers). Crossing up higher will eliminate a lot of that effect, as well as other problems. Driver don't work the same way on OB as they do in a box or pipe.
3) Cross it where it works the best. This is the school of thought I'm working in now. E.G. a 15" woofer crossed to an 8" FR at about 900Hz. Why so high? Because that is where it works the best for 1st order. This also allows some phase alignment for driver offset. Where the x-over point comes depends a lot on baffle size, and also on the drivers. Reasonably sized baffles have a bass roll off a lot higher than you might think. The idea is to forget the textbook values and go with what sounds best. An after the fact computer simulation of what sounds best can often lead to a "oh, yeah, now I see" moment.
As the filter slopes get steeper, the freedom to move the points around becomes greater. But with 1st and 2nd order filters the drivers will be working far beyond their x-over point, so you need to get it right.
All my opinion and experience, not gospel. Hope it helped some.
