Ok, here's how I have fitted a tophat to my Otop without it showing through the reflector.
1) Buy a slim top hat (Adam Hall make them).  
http://www.bluearan.co.uk/index.php?id=ADHSM701
2) When making the baffle (i.e. the first step on the way to an Otop) route a few mm into the wood on the FRONT of the baffle - like these pics:

 
3) Extend the woofer spacer down to the base of the speaker... this will ensure a more solid baffle (as if it needs it!)... the real reason for this is because the screws from the top hat need something to bite into, and by extending the spacer down, the screws can bite into the spacer AND the baffle.  Sorry, I didn't get a pic of this last night.  This arrangement also means that the routing of the baffle done in step 2 now has another piece of wood (the extended spacer) behind it... so you could go even deeper, which means you might be able to hit the speaker's c.o.g. AND routing it that deep would eliminate the need for step 5 (only just realised this as I type!!  

 )
4) Cut a hole in the base for the top hat to fit into.
 
5) Route a bit out of the horn reflector... this top hat is a TIGHT fit, so every mm you can pinch helps it fit.
 
6) Add in another bit of wood for the screws at the front to bite into
 
7) And if you have squeezed enough space in there, you should end up with something like this:

 
The top hat is hanging out a little on that last pic, but it does fit flush with the base of the speaker.  I did want to countersink it, but that would have meant finding even more mm (or sixteenths of inches)... my maths said it would work, but I think would be taking too much from the wood and it would end up almost paper thin.  This way, there is still plenty of strength in the wood.  
Fitting the tweeter cable can be a pain in the ass though, but I managed to squeeze it all in.  I know it looks a little rough, but it's all hidden, so I don't really care.  Time pressures are getting to me at the moment, as I have a big free party on Saturday night  

 At least the 2nd top (pictured) is now ready for duratex.  Still got a list as long as my arm, and I have just decided to also build a flightcase for my new mixer 

  Going to sleep well Sunday night!