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Ultimate DIY speaker design?
Great post Kschiu. I'm on my first DIY pair and should be starting a second shortly. If you have the time, patience, and know how, DIY is the best bang for the buck going. It also opens your eyes to a lot of things too...it will blow your mind how... 
Opinions on the Zaph Audio ZRT Revelator Towers ?
This would be better asked at DIYaudio, HTGuide, or the Part Express message board. 
Ultimate DIY speaker design?
These are shaping up to be some very impressive speakers: http://www.htguide.com/forum/showthread.php4?t=33995 
Capacitor log Mundorf Silver in Oil
Buying a second one now? :) 
Removing plastic phase plug from tweeters?
Leave it alone unless you're willing to buy another pair of tweeters. 
Help with distortion
http://www.audiogon.com/cgi-bin/cls.pl?accstwek&1256776619&/Goldenjacks-Audio-Attenuators-http://www.audiogon.com/cgi-bin/cls.pl?accstwek&1257597488&/Rothwell-10-dB-attenuators--rc 
Is rewiring worth it considering...
The description of the internals of your speaker does not fit all. Many use quality binding posts, soldered internal connections, etc... Maybe it's time for some upgrading.As for the thickness of voice coil wires...try using that wire from your am... 
CD Player Under $1.5k With Vinyl Sound
I'm not sure why you'd want a CDP that pops and clicks. 
CD Player Under $1.5k With Vinyl Sound
Check out the Marantz SA-15. 
KEF 107 - opening them? + other questions
If you can read a schematic and solder, crossover updates are easy. I would leave refoaming to the pros though. 
Capacitor log Mundorf Silver in Oil
They're very transparent and don't have a sonic signature like Mills or MOX do. Be sure to give them a few hours or so to break in though. 
Capacitor log Mundorf Silver in Oil
Fredrick, does it use the same leads as your other resistors? 
I want to try tubes, need suggestions
Unless it's to move up the Manley line, I don't see myself parting with the Stingray anytime soon. 
Capacitor log Mundorf Silver in Oil
I would cost me over $5700 to replace all my series inductors with CAST, and another $3500+ to upgrade my parallel inductors... When I win lotto. :) 
Would an external DAC be of any benefit to me?
An external DAC would be an improvement, but would be even more noticeable if you took the Onkyo out of the chain and went with a dedicated 2 channel preamp with HT bypass. Even a $400 DacMagic will sound much better than the Onkyo's internal DAC.