It's been a while since I've updated this thread, but I wanted to post the final products. I got lazy and didn't bother taking any build pics... That, and the Titans and 2 of the 3 Wedgehorns were built by someone else, so what you see is what you get.
Now that everything is completed our system is comprised entirely of BFM cabs, including 4 SLA Pros, 3 Wedgehorn 6 monitors and 2 Titan 39s. I have to say I'm extremely impressed with the cabinets. I've already commented on the SLAs, but since then I've been able to tweak the EQ a bit more to get them sounding superb. The coverage is exactly as advertised - Fantastic horizontal dispersion with a tight vertical window. Sometimes I need to leave the sound booth to get a better listen to the mix, as even being elevated a couple feet of the ground at the back of the room affects the listening experience. A good sign I have them aimed properly, but also a sign that our sound booth isn't ideally positioned anymore.
The Wedgehorns are vocal powerhouses. I had a lot of fun listening to them in my basement, trying out different tracks and testing the off-axis response (which is superb, I must say). Like the SLAs, I was pleasantly surprised at the midbass output from them. Not expected, but always appreciated.
They take up much less room on the stage than our old JBL monitors, weigh a fraction of the weight and have a wonderfully natural sound to them. I didn't even bother EQ-ing the Wedgehorns, as I don't think it's necessary.
The Titans... Sweet mother. I've never experienced vibrations like that before in the sound booth. Hard to believe all of that is coming from a pair of 12" drivers. We've had a single EV powered 18" sub and a single JBL AE series 15" sub in the past and the Titans eat both of them for lunch. We have them spaced out currently, firing into corners of the room on either side of the stage. Measurement across the room from wall to wall is about 57', so we're just a hair over the minimum recommended distance. When I initially fired them up it sounded like there were some phasing issues going on. I discovered that someone had wired the polarity on one of the Speakon connectors backwards, so once I fixed that there was a major improvement in coverage. I took some time to walk around the room tonight while playing music, and while there are a few "dull" and "hot" spots here and there, it's not too noticeable. I know it's ideal to V-cluster them, but the room setup makes that pretty difficult to pull off unless I put them up behind the stage.
The SLAs are currently running off a Crown XTi2000 in stereo mode, so each cab is getting around 400 watts RMS which seems to be a good match for the Alpha 6a drivers (not sure about the piezos/crossovers). Two of the Wedgehorns are running off a Behringer iNuke1000, and the third is connected to a free channel on our Crown XTi4000 (yikes). Don't worry, limiter set.
The other channel on the XTi4000 powers the two Titans, sending each one about 550 watts RMS. We recently (and finally) upgraded to a Behringer x32 digital console, so we've been having a blast setting it up and messing around with all the features.
I think that about wraps it up for this project! It was a fun build and it's all the more rewarding when everything performs as good or better than expectations. Props to Bill for the designs. It's hard to get a grasp at just how intricate these boxes are until you build one. It's all worth the blood, sweat and tears though.
Thanks for viewing!