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RE: Cornwal iii Squawker horn upgrades

Based on to Geddes (who generally does his research), what you are probably hearing are high order modes inside the horn (these get more objectionable as level gets higher). I think aluminum is likely to be more resonant, less well damped, than plastic. If all that is true, maybe your best move would be to get a block of 30ppi (approx) reticulated foam and carve wedges with an electric carving knife to fill your horns' volume. Attenuates the high order modes, doesn't cost much, needs no cabinet work, and doesn't change the outside shape of the speaker. No negatives, and it's reversible should you not like it.
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Make easy high performance diffusors:-->http://www.libinst.com/diffusers/Depot_Diffuser.html

Horn Design Spreadsheet:--> http://libinst.com/SynergyCalc/

SmallSyns:-->http://www.diyaudio.com/forums/multi-way/292379-s

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