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Since you asked so nicely: The 354 HF sounds a little bit like the BMS, which is absolutely not my cup of tea But the big difference which interestingly nobody seems to notice : 464 bands overlap, which makes passive crossover design pretty easy 354 bands underlap even without crossover

20-40Hz is M-force territory the other question is integration into the system without creating tons of group delay

464 is the best driver I have used so far for high SPL/Bandwidth 354 is not the same in a smaller package, it sounds very different

Some thoughts: BP designs may look good in Sim, but what happens if the driver gets hot. The more SPL you try to extract from the enclosure design the more the response can change with drive level. Hornresp gives the option to simulate Power Compression. BR designs on the other hand are pretty...

I have no experience with the horns above, but to me the Limmer 250M looks like a solution being right in the middle regarding size. Could provide enough loading down low to cross over to your 2x15" section and still have good HF dispersion. If it wasn´t Covid time, I would try out myself.

No delay needed to get good phase tracking.

Scrap wood is a lot of work to calculate volume, guess how I know. I´ve used milk ( comes in 1 liter handily ) and hard foam board like used for house insulation. Davids remark is important. Shortening the unused driver or connecting it to an amp without signal, probably slightly different...

Yes

internal standing waves

IMO you should reduce the volume for 12" drivers even further, something between 55 and 60 liter. I understand, that this might be difficult to achieve with your actual enclosure. Experimenting with damping material in different positions will show, if the 300Hz are

So you basically ended with a tuning similar to the suggested B&C design, which is probably a compromise for using the 12" fullrange, where it might be better to have at least some low end. For Top only application you are still waisting potential low/mid output. So whenever you find yourself...

In general general statements are wrong;)

Higher tuning by shortening the ports will help a little bit, but reducing the box volume would be way more effective in the frequency range from 80 to 150 Hz. But hey, if you only do light Jazz with the speaker.... Might be a good idea with this HF driver anyways

Why do you need a "rule of thumb" when you have the enclosure at hand. Some high power ( up to the maximum intended power level ) long sine sweeps with the High Pass, you would like to use in the system, in place should reveal problems in the pass band by adding noise. Just low pass the signal...

Another thing to consider, which Peter mentioned somewhat, but want to emphasize: An 80x60 dispersion will have lower SPL max than a 60x40 dispersion with the same driver. Lowering the crossover will also put more power on the midrange section. Since I´m using a passive crossover, I have no idea...

I see some different routes to go: - the hornloaded mid range with two 12" like Peters box but expanded. Problem for me is, that I would like to see the last horn section expand horizontally, which will complicate building. For the horn part there is no benefit going with larger drivers IMO...

Love the snare does´t go anemic when pushed. By chance I own 2x15" Tops with wave guides :) Until now DE1050 on TD460 was the HF driver. It served me well, but has to go for 462 on Limmer 264. Will make the killer rig for 500 people and maybe it can serve double duty as frontfill for my horn...

No idea about the RCF drivers, but don´t think these wave guides are critical. I would use 15NW76, because one can build pretty small enclosure, something like 90-100l for two drivers. Regarding US company making horns. DDS horns have a single 15" horn which looks like the perfect fit: DVB 15N...

Is there any benefit of using larger drivers over just making the horn bigger ?