yeah, a 6th using PR's won't need to be too much bigger than what you have now. It'll have similar bottom end to what you have now, but the upper notes will hurt a bit more for demos. You may want to pay someone for the design, but I bet with some monkeying around with driver/passive/port placement you could find something your happy with. Those are a 3inch coil right? If so I'd say getting hot around 1800-2200 watts is probably correct. Anything beyond that and your asking for trouble unless the motor was designed with extreme cooling in mind. 2500 tends to be the limit on 3" drivers, anything they take beyond that is just being abusive and won't do much for output longterm. What amp do you have on them and how much power? How big is the box?
Inside of the pole vent is pretty close to the coil and basic physics says the coil is going to be hot if you throw over a 1000 watts at it, 99% of that energy becomes heat. That's why I'm saying 6th order. The impedence spikes mean you'll be sending 1/3 or 1/4 the power at the higher range of the driver where it's moving less, but still getting more output lol. I did a 6th order for a 6.5 one time rated at 100 watts and I could put a 250 watt amp on it and ran it pretty hard, it wasn't blowing. The speaker only saw near it's nominal impedence for like 10hz worth of range betweeen 45-55, everywhere else it was pretty well protected thermally.
Inside of the pole vent is pretty close to the coil and basic physics says the coil is going to be hot if you throw over a 1000 watts at it, 99% of that energy becomes heat. That's why I'm saying 6th order. The impedence spikes mean you'll be sending 1/3 or 1/4 the power at the higher range of the driver where it's moving less, but still getting more output lol. I did a 6th order for a 6.5 one time rated at 100 watts and I could put a 250 watt amp on it and ran it pretty hard, it wasn't blowing. The speaker only saw near it's nominal impedence for like 10hz worth of range betweeen 45-55, everywhere else it was pretty well protected thermally.