Radio Shack MINIMUS 7 crossover upgrade

My first reply to your question doesn't seem to have made it past the moderators, perhaps because I gave the user ID of the guy who sells replacement crossover kits for the Minimus 7.

I don't have any connection to him other than having bought three of the kits and been very happy with them. He sells the kits on ebay and if you search for 'minimus 7' you'll find them.

The instructions that come with them are pretty primitive but it's definitely worth the effort to figure it out. Just take your time, stare at the innards of the speaker for a few minutes and you'll do fine.

The only thing that takes a little figuring out is where to mount the new crossover board so that you have enough clearance to put the woofer back in. I used a hot-glue gun to stick it against the side wall of the speaker enclosure.

I recently replaced the crossover in my Minimus 7s. I considered the kit that Sfar refers to (sold on ebay), I also searched Audio Asylum where there's lots of advice. In the end I simply built a 1st order crossover from parts I purchased at Parts Express. I also replaced the sprung wire connectors with good 5 way binding posts. I used acrylic from Home depot for the structural parts (ie to fasten the caps, inductors, and binding posts to). The only challenge was positioning the cap so it wouldn't interfere with the woofer.

This is an easy DIY project, even if you haven't done anything like it previously figuring it out yourself is a good learning experience.

Wow there are quite a lot of audiophile people still using or have knowledge of this Minimus 7 speakers! :)
After reading replies from these knowledgeable agons members and a little from google (not much there unless somebody can point to me the info), can I ask some follow up questions?
1. What is the recommended type of capacitor and value to replace the existing one inside?
2. What are the components to build the low pass filter for the woofer? How do you connect these components together with the woofer? How do you choose between cutoff at 2khz versus 3khz?
3. The fiberglass material should be replaced inside. What are the recommended material and how dense should it be stuffed inside the cabinet?
4. Should the woofer be doped like the suggestion above? Do you paint inside and outside? Would this make the speaker less efficient and perhaps change the lower frequency as the movement of the woofer is lower?
5. How easy is it to remove the metal grills off these speakers?

Thanks for your forthcoming replies on this! :)

The original kits were sold by a long-defunct outfit called Soundaids (separate kits for minimum 7 and the larger Minimus 77) Lngbruno has all the basics right. This is really worth doing -- especially for the 77, which produced an amazing amount of tuneful bass for a speaker this size. Good luck, Dave