I have since swapped out the 1200hz smith horns on this project with full scale 2397 replicas built from heavy beach-wood driven by 2440s. The 2397 were constructed in the workshop in much the same way as the smaller horns. These mate very well with the E145s, and actually sound much better overall.
I built some grills for the fronts to make the wife happy. Since a nice curve doesn't hold its shape when stretched, the wooden frame was first faced with a fine wire mesh and then covered with the grill cloth.
I have also switched to using an 5234 active crossover with an 18db slope at 800hz to the E145 and a shallower slope to the N333 for the mid and tweeter section, sort of like the 4430 card.
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