I decided to build these - http://www.troelsgravesen.dk/DiscoveryW18.htm. Reasons for the choice were: 1) The mini 4" ScanSpeak driver I tried before gave me a taste of the clear resolving sound of the discovery drivers 2) Price was about right - around £600 all in. Still the most I have ever spent on speakers, DIY or otherwise! 3) Building the Overnight Sensations has temporarily turned me away from single drivers towards 2-ways. The crossover components come in a kit from Jantzen. Even including shipping from Denmark I couldn't have sourced the parts any cheaper locally. Also included are ports, damping materials, wire and binding posts: €280 for the version with Jantzen Superior Z-caps. Drivers from Falcon Acoustics - £80 for the R2604 tweeters and £110 for the 7" Discovery Woofers. All the information is on Troels Gravesen's website, including the theory behind addressing time-alignment issues with the stepped baffle. My build is documented below in case anyone else fancies having a go - I highly recommend it! Listening impressions and measurements are towards the end. Rest assured, these sound terrific. PLANS: I asked Troels if it would be okay to use 18mm ply throughout. No problem, he replied. Here are some plans I drew up in SketchUp to help me. If you do use these, please only look on them as a guide and refer to Troels' plans as the ultimate reference. These use mitre joints - you don't have to! CONSTRUCTION: 1) Gluing up mitre joints can be a great way to raise your blood pressure into unhealthy levels. I cut slots for biscuits in the mitres to make alignment easy. A new toy! - a Lamello biscuit jointer. This thing is awesome. Rock solid and 100% accurate. You can just trust it. 2) I also cut rebates for the back panel and slots for the horizontal braces. I use a router/guide rail system and cut both sides at the same time to help ensure alignment. The Dewalt system is not the worst POS, in fact it's fine in many respects. It lacks a bit of quality. 3) I made the brace holes with a hand drill and hole-saws. I'm drinking the Festool Kool Aid (Festool-Aid) these days. 4) Here are the pieces for 1 speaker frame ready to go. 5) Glue-up can be done with strap-clamps. Several other regular bar clamps were needed to pull it into place and to put a squeeze on the braces. 6) Front Baffles: The pivot point for the curved outer baffle sits just inside the recess for the woofer (more or less where the bottom mounting screw is located). After cutting that, I moved on to the rebates, driver & port cut-outs and chamfers on the reverse. 7) DAMPING An optional step is to use 4mm bitumen pads on the inside walls to help with cabinet resonances. The cheapest I could find was 'Bitflex' on eBay. It's only 2mm, which meant 2 layers were required - a bit of a pain! As recommended by Mr Gravesen - use elastic vinyl flooring glue. ...then a layer of wool felt. Strategic pieces of acoustilux are also used, as per the plans. 8) One thing that I've found a bit annoying with previous builds is how the baffles will tend to slip around during glue-up. To eliminate this headache I used dowels and biscuits for alignment. It's really nice to be able to just concentrate on a good clean seal, and not worry about slippage while clamping. I've switched to Titebond Extend for glue-ups. The longer open time is really useful and much less stressful than Titebond I which becomes unmovable in about 2 minutes! The baffle overhangs the sides by a mm or so, so it can be trimmed flush. At this point I flush trim the back too. It's really a nice way to get a clean finish on the exposed laminations. 9) Cutting the chamfer (25 degrees) on the front can be a bit daunting. I use the other speaker to help support the router and clamp a bit of wood to the exit point to avoid tear-out. 10) FINISHING: Since all edges were trimmed with the router, very little sanding was required. A cabinet scraper can be great for carefully removing any glue residue. I then applied 2 coats of hard wax oil and then wax polish. The wax polish is a labour of love - lots of buffing! In one of the pics below you can see how large these speakers are next to the Overnight Sensations. Next...crossovers!