QUOTE (Blackrazor)
If you want to be safe, i normally install a cap HPF set to one octave below the normal HPF point you have the tweeter set at, has never failed me yet

so if the tweeter normally plays to 2500Hz, you set a HPF filter to 1250Hz?
i wouldn't advise that, i think you mis-worded your post!
To my understanding:
passive Xovers are calculated using the "roll off point".
this means that the frequency used to calculate the caps and coils is where the cap or coil STARTS to affect the frequency response.
when you use an active crossover, the crossover frequency is actually the -3db point (explanation further down)
on this basis, you'd be wise to pick a HP point a little higher, and a LP point a little lower than recommended, to account for this.
also, with a 1st order HP filter, i recommend you chose a frequency higher than usual, to help reduce the low frequencies to the tweeter
now... since you're goign 3 way, if you intend to build filters for each driver, then i suggest you use 2nd order.
crossovers cause phase shift at 90 degrees "per order"
so a 1st order crossover has 90 degrees shift
a 2nd order has 180 degrees shift etc.
now for your midrange, you'll need a HP AND a LP. this means the phase shift will be exactly double that of the tweeter (as it will only have a HP)
if you use 2nd order filters, you'll have:
midbass (lp only) 180degrees
midrange (LP + HP) 360 degrees
tweeter (HP only) 180 degrees
now, wire your tweeter and midbass in reverse polarity and all 3 components will have 360degrees of phase shift.
this will aid you greatly in imaging (which is what 3 ways are all about)
(explanation from above)
using the -3db point for crossover points is quite important IMO,
if your midrange and tweeter are both crossed over at 3Khz, (where each driver is at -3db at 3khz) both drivers will assist each other to provide a flat overall response (on paper)
if this sounds too complex, then you should be doing more research before you embark OR get 6 channels of amplification, and an active crossover.
there are some crossover calculators at
http://www.carstereo.com/help/Articles.cfm scroll down to
"Crossovers & Filter Calculator"