Thanks for the feedback folks. Been off-line over the holiday, so I haven't been able to respond until now.
To answer the question "why not go active?", I am... for the bass. I use an active analog pro sound crossover for stereo subs and for high and low passing the RM30 woofers. What I want to avoid is running the mid/highs through the crossover since the opamp based unit noticeably colors and diminishes the sound. Below 300Hz, using the active unit is a reasonable compromise because the gain in woofer control, and blending driver outputs to the room more than make up for the unit's coloration. Above 300Hz, where all I need is a high pass filter, the sound quality of the active unit is not acceptable.
Davey, I tried searching for the kind of inductors used by Marchand and couldn't come up with anything. Maybe I'll get the inductors and crossover boards directly from Marchand.
Scott, sounds like we're on the same trajectory regarding the RM30s. Are the "pot in a box" filters in series to protect both Mid/Tweeter or is one filter for the midpanels and the other for the tweeter?
Right now I do have a 400Hz 1st order filter on the input of the Mid/Tweeter amp. Since I removed the speaker's cap-coil high pass filter, the 1st order filter keeps the bass out of those midrange panels. The link to those hlabs filters gave me the idea of using multiple 1st order filters to get a steeper crossover slope. I'll have to experiment with that.
Thanks again.
Russ