Hi Guys,sorry for the late reply, my wife doesn't see my urgency about this,so im going with the flow!!,please bear with me.
So,i now sat here with one of the crossovers multi meter in hand and i will try answer al the questions
DC offset,taken at speaker cable end ,speaker removed
repaired amp mid/high left chan 0.000 right chan 0.001v {DC]
bass amp Left chan 0.006 Right chan 0.002 {DC]
on xo IP pos and IP neg have good solder joint{tested good}
resistance between IP POS And IP neg -OL ,
Multi meter checks out good,i have two of them ,both reading close enough.
No visabe shorts on board or speaker terminal board
mid speaker cable going to driver,dead short.no driver connected
tweeter spaker cable going to driver ,dead short,
no driver connected
bass cable going to driver. OL,
no driver connected
ALL 3 OF THESE TESTS WERE ALSO TAKEN FOR XO PCB END
internal speaker cable from input to xo,No shorts
Test for shorts done at speaker cable imput {4 terminals}for bi-wire and Bi amp,inputs at the back of speaker boxes, NO shorts
to test resistors do i need to remove one side from pcb xo,ive just tested one [5w2R2J] and it showing a short,still fully soldered ??.
on the comments about capacitor placing on top of resistors etc,i do see what you mean,it was my first time replacing the caps on an xo and the leads where short,but i can remove the all and try again,its just that these caps are a lot bigger than was what installed at factory,sorry for my rubbish placement.
so all in ,i see no physical short, wires touching, all soldering has been tested for contin.all good,no dry joints,no cable fraying,no cable rub throughs,from vibration,it seem to me listening to you guys i maybe need to remove all components and test them,would i be wright in that assumption
,hope the wife doesnt mind me spending the next day or two doing this !!!,shes wanting a garage built !!!.
Anyway guys,i hope ive answered all you questions,i sure do appreciated you all taking the time out to help me with this,.
Kind regards
Mark
PS,im still open to tri-amping if you think it might be a better solution ,in the end,fiesta,but would be great to find the problem first,Anyway
cheers guys