duramax747 - are you going outboard with the 2.4s? I have a feeling that is the route that will be taken but the stubbornness in me wants to explore the internal crossover further.
There have been recent posts sending me down rabbit holes. Similar to what Rob posted above, it seemed beneficial to create a schematic and studying the crossovers design. Been toying with an internal 2.4 coax board layout with electrical components on both sides. Tom Thiel mentioned "signal chaos", point-to-point and two-sided layouts so it seemed worth jogging that path to learn more. The design considers a short path with input/output separation, component orientation, star ground (simple) and hopefully sufficient thermal management.
Another rabbit hole was the mechanical and electrical vibration discussion then how to edge mount a two-sided layout. Since using simulation software is not likely in the cards, perhaps an accelerometer will work. Not sure how to avoid custom brackets and can print TPU to see how that measures. TomD mentioned a mechanical approach to vibration but couldn't figure what it was or how it could be modified for this design.
Those rabbit holes certainly reaffirms previous "it's complex" comments. Good grief it is and it must have been an exceptional team to create Thiel products for so long.
Think a few of you are on the Facebook page and might reach out there if interested in seeing the layout. Never fails I post photo watermarked "Do not use, designed by a 5 year old Lego expert" and creates confusion. Still can't direct message here.