They designed those "subpar" crossovers because those components worked and they could buy them at a price that Paul Klipsch would pay. The technology had changed a lot between the time Klipsch started and when Bob started doing his work- what's to wonder about? Ever seen the electrolytics in Hersey speakers from the '70s? Big and rectangular. They used terminal strips for the connections and nothing fancy.
What was available from other manufacturers, at the time (of Klipsch origin, not 20-30 years later)?
I called Bob once, for Heresy tweeter questions- he wasn't impresses by the 'tweaky' modifications and cable marketing, either. We had a few good chuckles- nice guy.