I know what you mean, my belt sander weighs over 1kg and really is tedious to use that way.
These days I make one thin, ie 8 - 10 mm, mdf template and then use a router with a straight edge bit with ball bearing wheel to shape the rest.
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Do you have access to a SPL meter or REW?The woofer is not going down without a fight - which I expected. I.e. it is competing with the Tweeter above 2200hz. (4,000 I can't hear the woofer at all)
I could order new tweeters...just so many out there. Maybe one closer to 89db - 90db.