The crossover is the heart of any highend loudspeaker effort, where enclosure design is done with pure high tech science and research and development the crossover is as much a dark art as a science.

The shear number of crossover topologies and iterations within those topologies that are available to a designer are endless! What add on circuits to apply when and for what ailment a design has at its particular stage of development is a task for an ordered mind.

Let's first talk about the individual components that make up a crossover.

Inductors.

They should be Aircored and as large a gauge as the budget and practicality can allow. Low tension winding double stabilized in motor winding varnish or ideally boiled and encased in bees wax. As a general rule of thumb a high-end design effort should use a bass circuit inductor that weighs at least the same as the bass driver itself. In the ML1 Signature it's actually heavier at 1.2 Kilograms for the inductor verses 1.05 Kilograms for the bass driver.
In fact the factory control crossover bass inductor for this design weighs double that of the bass driver.

Small gauge inductors reduce the damping available to the bass driver which in turn reduces the grip or control the amplifier has over the cone, it can't start and stop without overhang(a little like a boxer whose glove is connected to his elbow with a rubber forearm, he couldn't jab with speed or precision ).

All Inductors used by LenehanAudio are wound and toleranced inhouse by ourselves.

Capacitors.

A range of capacitors are used in our loudspeakers starting with Mundorf Mcap in our entry level models then moving up to Auricap in the Signatures and finally to the Dueland copper foil caps in the level 2 signature designs.

Capacitors do make a difference, unfortunately they can be very expensive!!

Resistors.

Resistors are very important components! We use only Vishay high-power wire wounds(5watt to 20watt) with Temperature Coefficients in the 30ppm to 50ppm range.

Cheap resistors compress dynamic range. Let me explain 10 watt sand-cast resistors (square bodied white in color) with temperature coefficients in the 250ppm to 750ppm range work to compress the dynamic range of a loudspeaker.
Let's say we have an 8ohm resistor attenuating a tweeter in a two-way loudspeaker, all of a sudden a musical transient comes along which hits that resistor with a pulse. A cheap sand-cast will momentarily increase it's resistance until that transient is gone. This behavior is linked to the temperature Coefficient of the resistor. So here then is a device that works like a perfect dynamic range compressor.

Good resistors however with very low temperature coefficients are virtually transparent to the signal but cost between 10 to 15 times as much as cheap sand casts.

Connections.

All crossover components are hardwired component lead to component lead then crimped producing a high pressure low contact area cold weld, finally the joint is sealed using Eichmann 5% silver solder.

This method of connection is State Of The Art and infinitely superior to even the best circuit board.

Can you imagine taking a $106 Silver Oil capacitor and poking it's output lead into a hole on a PC board then blobbing on a lump of solder?! this spells information loss.

Solder is not a good conductor and it's use is based mainly on manufacturing convenience.