Please excuse me if i haven't read the thread properly, but what did you do about the tweeters? Did you buy new ones?
Reason for askin' is that i had the very same tweeters in my Dali 40 speakers, and these had a reputation for getting sticky with age and consequently blowing the voice coil easily.
Anyways, i bought a repair kit for mine, consisting of an assembly with both the dome and voicecoil, easily replaceable. The did sound a little harsh and grainy though, after repair... Seemed also to add quite few decibels of efficiency which meant i had to tune them down a bit with a series resistor of about 1,5Ohms.
In the end i converted my Dali's to 40SE spec. instead, using ScanSpeak 2905/970000 tweeters and adjusted x-overs. Result was a thouroughly more enjoyable loudspeaker!
Beautiful job by the way, the speakers sure look good!
BrMike

