In reply to:
How does this effect the damping factor?
The damping factor is an easily calculable function of the resistive network used in the filter. Assuming you're even using an inductor with a lower internal resistance than the original design (which I've not seen you demonstrate is the case with these speakers), the effect will be a (very small) change in the total resistive network.
A damping factor of 2^.5 produces minimal overshoot. In the case of your upgrade, have you calculatedthe original circuit's damping factor? It may very well be pretty close to 1.414 (and I'd expect it to be) and you may very well be pushing it away from this critical value, thereby WORSENING your filter.
