the 630V caps and far-more-expensive Mundorfs et al were simply too big for the space on the XO boardThe higher voltage versions, with thicker film, are reported to sound better. I didn't compare different voltages on the coax feeds but did directly compare 160 and 250V versions on the woofer shunts. Some say that shunt cap quality makes little, if any, difference in SQ but, to my ears, the higher voltage version sounded a bit more relaxed and with more bass heft and impact. A subtle difference but one I am willing to pay for.
In my case, the larger caps were not an issue because I started with completely new boards/layout. So, no need to fit a new cap into an existing space.