Many of us who frequent the Klipsch forum and work mostly on Klipsch often go to Parts Express for caps. Lots of non polar electrolytics out there but in general I replace them with poly caps even though they are much larger and may require two to get the right value.
What exactly did you replace the OEM caps with? Brand, type, UF+tolerance and voltage.
I have rebuilt hundreds of Klipsch crossovers and never had your problem so I am also wondering how hard you are pushing them. I bought a pair of KP-262's once that had melted the rectangular blue mylar caps but it took really serious abuse to get there. They still played but did not sound very good.
What exactly did you replace the OEM caps with? Brand, type, UF+tolerance and voltage.
I have rebuilt hundreds of Klipsch crossovers and never had your problem so I am also wondering how hard you are pushing them. I bought a pair of KP-262's once that had melted the rectangular blue mylar caps but it took really serious abuse to get there. They still played but did not sound very good.