Is BSC something that should be considered after listening to the speaker without it? Or should I go for it now while still in the construction phase?
Yes, you should go for BSC in the construction phase. Often when people are designing their own crossover, they listen to the speaker mounted in its cabinet, while a mock-up crossover sits outside the cabinet with wires running inside to the speakers. Crossover parts are simply clipped together without soldering anything yet until a final design is made. Yes, it is necessary to make the crossover board small enough to fit inside the cabinet - not always easy
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The soundhobby calculator offers different steps of correction which leads me to believe that the speakers should be tested for the actual effects of baffle step before the network is made...which would be difficult to install inside a speaker with a 3 inch hole
If you already know where you will place your speakers, relative to the wall behind them, you can make an educated guess about how much BSC to use. If the speakers are going to be very close up against that wall, you can skip BSC. If that distance is going to be roughly 18" or more, use the full 6 dB compensation. If the speakers will be somewhere between 0" and 18", try using 3 or 4 dB compensation.