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For the transition smoothing, are you talking a fine-wheeled dremel/good eye, or machine shop work?
Would a DIY, short "spacer", with its' opening having the same expansion rate as the driver, and thick enough to match the horn ID be advisable, or better to build/buy a matching horn?
..........I ordered new glasses last week.........
<font size="2" face="Verdana, Helvetica, sans-serif">I used a three stone brake master cylinder hone on a variable speed drill. You can use a spacer if you want. The main thing is for the first expansion to be as free of anything that can create a reflection point since this is the area of the horn covering ~4300 Hz - up.