Sean, Flo'Dolo,
Sorry for the long delay in my response. I've been using up my vacation days that I never got to take in 2002. Now, unfortunately, I'm back to the grind.
Distortion Measurement
There are various techniques and a lot of specific issues but in its most basic form you drive the speaker with a sine wave and record the output with a high precision microphone. When you put that recorded signal through a spectrum analyzer you get a large peak at the frequency of the input sine wave and several smaller peaks resulting from distortion induced by the speaker. The heights of these extra peaks are measured relative to the height of the main peak and given as percentages. This process is done for many different sine wave frequencies so the percentage distortion values can be plotted a function of frequency. Often you will see the primary 2nd and 3rd harmonic distortion values plotted. Otherwise all the peaks are summed together and the total distortion as a function of frequency is plotted.
Intermodulation distortion is measured similarly except two sine waves with closely separated frequencies are used instead of a single sine wave. The harmonics of each of these sine waves are ignored while the sum and difference frequency peaks are measured to determine the percentage of intermodulation distortion.
I've attached a distortion plot for probably the best 6.5" midbass woofer available today. You can see THD is around 0.3% in the midrange. As you go down in frequency the distortion starts shooting up dramatically. It's about 5% at 60Hz. Now remember that this distortion is the harmonics of 60Hz. In other words, false signals at 120Hz, 180Hz and higher which are clearly audible at -26dB. And also remember that this is for the very best 6.5" midbass driver available. This driver has much better performance than the midbass drivers in
a Mackie HR624 or even
a Genelec 1030A, so you can imagine how bad their curves look.
Deep Live Bass
For live mixes you probably do want to weight the mix more heavily towards the low end. But despite the fact that you may have large subs, pro sound systems often do not reach much lower than 40Hz. For live situations personally I remix my music specifically for the system I will be playing through. The place I perform most often is my friend's 4000s sqft graphic design studio which doubles as an unofficial dance club about once a month. There I built them a custom sound system with subs that begin rolling off shallowly at 32Hz. Their closed boxes and shallow slopes allow them to still produce significant amounts of well controlled energy down to 20Hz. So when I'm performing there I don't use any hi-pass filtering on my mixes. When I occasionally play through other systems that typically roll off at 40 Hz using ported speakers it's important to cut out the very low content. Ported speakers are extremely uncontrolled below their lower cutoff frequencies and basically require hi-pass filtering. So check out the specs on the subs you're using and roll off the lows appropriately.
Subs
Subs are a great idea. Not only do they give you extra bass extension, but they also free the monitors from all that deep bass allowing the upper frequencies to run more linearly. Yeah, you should definitely go with 624s plus subs over the 824s. The 624s have better midrange anyway.
I do build subs. The design I most typically build is an 18-inch super linear, extremely long throw driver in a rock solid 4 cubic foot closed box. Like I mentioned above, the lower f3 is 32Hz and the shallow roll off helps produce very accurate very low bass. I always recommend a pair for stereo. I hand build the electronic crossover myself, tailor the curves to the particular monitors, and can even incorporate active bass compensation circuitry to bring the f3 even lower.
In order reproduce very low bass you need to move a lot of air. The laws of physics dictate that in order to this you need a large speaker in a large box. The only good way around this is to use a smaller speaker with an extremely long cone travel in a smaller box and active feedback control like the F and HGS series subs made by Velodyne
http://www.velodyne.com/.
barefoot