Hi dragonxwas,
I am not an expert in electronics and not at all a person gifted with diy skills, neither am I an audio-guru of any kind. But I felt there are a few things mentioned in your post which may be a bit misleading. Please take this post in the right spirit. BTW, I see that you have recently joined our forum, and let me take this opportunity to welcome you.
You have rightly put a lot of importance on the issue of impedance matching and the lowest impedance an amp is stable against. There have been detailed discussions in many threads of this forum, where people including me have discussed this issue at length, and various other issues like sensitivity and efficiency, speaker excursions and distortions etc etc.
Based on the above, your comment "most of the posters above don't know why an amp clips" is at the least a bit presumptuous.
Unfortunately, I do not have the time at the moment to go into details of your post. I will just comment on your last point.
You do not think clipping would harm speakers, because the DC can be bypassed using a protection circuit. I do not think this is true. That protection circuit (modification to the crossover) will take care of DC alright, but then one needs to understand what is the Direct Current (DC) in the clipping context. Unfortunately, these days I am always in a hurry, and I did not take the extra care of explaining these in detail in post #22 (
http://www.hifivision.com/surround-...ed-amps-vs-overpowered-amps-3.html#post227462).
Let us concentrate on a sinusoidal wave form (hence comprising of a single frequency). In general, a musical signal comprises of a wave-form which is a linear superposition of many such sinusoidal wave forms each corresponding to a definite frequency. For our purposes, a simple sinusoidal wave-form is enough because the actual musical wave-form can be broken up into these sinusoidal ones.
Now, when clipping occurs, there will be flat portions near the crest and the trough of the waveform. The clipped waveform can be analyzed through a Fourier decomposition. This actually will lead to the following: the clipped waveform (originating from clipping of a sinusoidal waveform of a single frequency f) is actually a superposition of many sinusoidal wave-forms corresponding to the fundamental frequency f, and its odd harmonics 3f, 5f, 7f ... (the odd harmonics appear if the clipping is symmetric around zero, that is, between top of the waveform and the bottom). There is one more twist to the tale: amplitude of the waveform corresponding to the fundamental frequency f after clipping is significantly larger than the amplitude of the original sinusoidal wave-form with the freq f. Amplitudes of the waves corresponding to the harmonics like 3f, 5f etc are monotonically lower, however, they are significant (that is, not very small). Now remember that the power a particular wave carries is proportional to the square of the amplitude.
From the above, one concludes that after clipping of sinusoidal waveform of a single frequency f, there are many sinusoidal waves. The fundamental one corresponding to the freq f now carries significantly more power. In addition, there are other waves present (corresponding to higher frequencies 3f, 5f etc) which also carry significant but lower amount of power.
Now, remember that the tweeters are really delicate objects, surely much more delicate than woofers. If a speaker is rated to handle 100W of power, the tweeter is probably good enough for 10 Watts or at best 20 Watts. The crossover saves speakers by forwarding high frequencies to the tweeters and lower frequencies to the woofers. There is of course no sharp demarcation at the crossover frequency, some low freq also go through the crossover to the tweeters and vice versa (of course this a different topic altogether, and tweeter damage can also occur from low freq going to the tweeters).
Now one realizes why clipping is so dangerous to the tweeters. Such a delicate thing is subjected to significantly more power, even from the component of the wave with the fundamental frequency f (this is a point not usually mentioned) and also all the power (albeit lower) from the components having higher frequencies (odd harmonics of f).
The bypass/protection circuit you mention in your post is designed to bypass DC, but it will do NOTHING to protect the tweeters from these clipped signal which will carry significantly higher power (both from freq f components and higher freq components).
The reason your bypass will not work is the clipped waveform is NOT DC. It would be pure DC if the flat portions would continue for all time. But a clipped signal is not like that, it has DC segments, but overall the signal is still AC (the flat portions appear periodically above and below zero). People colloquially call it a DC, but it is actually not. It is actually a more complicated AC waveform as I have elaborated above, comprising of many frequencies. At best it can be called a DC segment, a segment when the signal does not change in magnitude or direction over a restricted period of time. It is also in this very restricted sense, in my post #22, I called it a DC. There was another reason for me to call it a DC in reference to the valve amps with transformers in the output stage. It was then easy for me to explain why that steady portion will not go through the transformer primary into the secondary because of its property of not changing with time (albeit for a restricted period of time).
There are a few other parts in your post I am not entirely happy with. However, I shall stop here.
Whatever I have written are established facts and analysis of physics. I must say though there may be other reasons or explanations for tweeter damage occurring from clipping. Some physicists have worked on these things. However, the scenario presented here remains as the most promising explanation, although I have seen some heated and emotional discussions (including sarcasms) in diy forums even on the stuff discussed here.
Regards.