You choose drivers…
This is important especially finding the right combination of drivers to give
best synergy across the audio band.
You look at freq response graphs for drivers…
This tells a tale about the drivers but doesn't tell everything. You have to figure
out what region the drivers work best in, ie a cheap mylar tweeter will probably
be crossed over at 5khz or higher where a quality dome might work down to 2khz, or
a horn driver may work from 2khz and up but drop off beyond 12khz... etc ...
One you figured out the basics you can rule out combinations that don't work
and focus on ones that might work.
You figure out where the graphs get ugly and mess up, choose a crossover point which does NOT include the bad parts
The crossover is the minimum requirement, meaning it will pass high frequencies
to the tweeter and only pass midrange frequencies to the midrange drivers and
pass lower frequencies to the woofers. This would be a 3 way example.
The crossover is like a frequency splitter sending the signal to the proper drivers.
There are different types of crossovers;
http://www.audioholics.com/techtips/audioprinciples/Loudspeakers-Crossovers.html
Four type shown.
Then, there is different crossover slopes on can use, 6dB, 12dB, 18dB, 24dB, etc.
So, once you figure out which type you want and which slope for a particular
design the next step is to figure out if the drivers themselves have issues within
their operating range and if you have problems you have to change your
mind on crossover type and/or slope, perhaps add more electronic circuits [filters]
to fix the response [EQ it].
Then, you have to look at the impedance of the driver across it's passband
to see if it drifts from nominal as you may have to add a zobel network to help
keep impedance more constant otherwise if impedance drifts alot, your crossover
point changes.
The crossover design will make or break your system if you don't get it correct.
Now, since this is DIY the active setup is superior because many of these
issues are easy to solve.
For example, using a digital crossover in a active system;
*You don't need a zobel as impedance variation doesn't matter {unless you
are using a sensitivity tube amplifier that doesn't like lower impedance}
*Filter type/slope can be selected in real time.
*Crossover frequency can be changed in real time in increments.
*These digital crossovers have parametric EQ's to fix issues if needed.
While this is cool you still have to understand what you are tweaking.
Most people that make loudspeakers just pick drivers that might work
well together and try to use simple crossovers to keep it simple, so
passive crossover design can be easy if you have drivers that are 'easy'
or it can be a PITA if the drivers you choose are difficult to work with.
If you really want to understand this, you need a active crossover test bench
otherwise it will take you forever to really understand what is going on.
There is also the 'full range driver camp'. Where you use 1 driver to cover
the whole audio band without using crossvovers. The problem facing this camp
is getting high end and low end extension.