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Guess I should update this I received the 2nd surround kit and the first woofer dried and I tested it. It rubbed just like the first time. I just gave up and went to bed early. Next day I tried the other woofer and it was perfect. I was newly inspired so I decided with nothing to lose on the failed woofer, I peeled the surround off the metal basket (pretty easy, the glue didn't have a death-grip on the sanded metal) and re-glued it making sure everything is aligned. It still rubs now but only at 1 oclock on my amp (normal listening is 10-11 oclock) so I think it's safe as long as I don't over-drive it. Both are back on my desk making all kinds of lovely sounds. I'm currently saving up to re-do the crossover circuit. I will post pics when I do that as well.

I finally got around to ordering new capacitors for the crossover. I picked up some Mills resistors too. Took me 2 days to rewire the crossovers since I chose to braid new internal speaker wire and solder everything. I honestly can't say I hear a difference, good or bad. The only comfort I have is in the fact that I have $110 max in these speakers and now they're in "refurbished" condition so if I ever wanted, they should fetch $350 or so to the right buyer.

Wow, looks like a superb job. The braiding must have been a bitch.