Well, a rasp and 15 minutes of heavy filing did the trick. I still put a thin layer of cork around the hole as the speaker braces still hit the sides just a little and I was already hitting the metal screw inserts with the file on all of the screw holes. Fits nice and snug now!
I realize one of the problems with the speaker is that it is really made to fit a cab from behind, not drop in from the front like the MM's are. The front of the EV has the heavy cardboard ring on the front so you can mount it from the back. Not so on the speaker's rear of the rim. So, even though it's a bit of mis-installation, it works. I am going to add some longer screws with washers as the stock screws barely hold without pulling through the holes in the speaker rim.
I'll ad some longer screws with a washer tomorrow. Otherwise, all is well! Meanwhile, I cranked the amp up and the sound is amazing. When I think back to how thin and nasally it sounded when I first got it, I'm amazed the difference $200 worth of speaker and stuffing make. It thumps, it's bassy, it's clean and no farting at volume. I'm so pleased. The casters also rattle less, so I'm thinking I'll leave them on for a bot. They are handy for moving things.
I recommend the acousta-stuf without reservation. I put 5 lbs. in the cab and it sounds terrific. I'm ordering 5 lbs. more for the other cab (about $44 with shipping). Not cheap, but easy and effective. I'll leave the JBL in that one and it should sound great as well. It's so nice not dealing with fiberglass issues. You can handle this stuff with your bare hands and no mask. Just stuff it in.
After I stuff the second cab, I'll take the cabs back to practice and report back on full bore operations in the club.
