Have any of you ever replaced Magnepan 1.7 or 1.6 tweeters?

toolbox149,
   
     I think you may want to consider more thoroughly identifying the problem before proceeding to fix it.  It could be some magnets, that are connected at various points on the stretched mylar panel, have loosened and clatter when driven hard.
     I had tis with my 1st pair of Magnepan IIBs years ago.  I didn't think of it as a tweeter issue, however, and noticed it more on the bass and midrange in my speakers.  At higher volumes I noticed a clapping or clattering sound that was more like a vibration.   After researching on the internet, I discovered this was a somewhat common issue that was caused by the glue that Magnepan used at that time failing.  Magnepan had found a glue from 3M that remedied this issue. I decided to just buy a newer pair of used 2.7qrs rather than send them to Magnepan for regluing.
     Your 1.6 or 1.7s are newer and it sounds like you'd rather have them repaired.  So I'd suggest calling Magnepan to get their thoughts and a quote on repairs.  I understand you're  handy but it may be best to have them professionally repaired. I know boxing them up and shipping them to Minnesota is a pain but they may already have developed a better glue and process. Plus they'll likely give you a limited warranty on the repairs.

Hope this helped some,
    Tim

Thanks,
Actually, I received an estimate from Magnepan and the cost of their estimate, plus the freight to and from Minnesota, was as much or more than the 1.6s are worth.

Toolbox

time for some 1.7i

the x.7 are a big upgrade...

     That's a good idea, Randy.  The 1.7i are reviewed as being a big improvement from the 1.6 and 1.7.
     Maybe toolbox149 could find a dealer to take his speakers as a trade-in.  Let them repair them if they're willing.
  Tim

IMO, since the speakers aren't really "functional" in the audiophile sense and since sending to MN isn't worth the expense, you really have little risk of trying to make the diagnosis and then repair on your own.  I have re-socked a pair of 1.6s and it's really not at all difficult. 

First, each of the wood trim strips must carefully be removed.  Use a long, but thin screwdriver and start from either end.  Insert the blade of the screwdriver between the panel and (parallel to) the wood strip and very gently pry a little then push the blade further along--keep repeating.  The wood strips are held in with small brads/pins and release pretty easily BUT if you pry too much when the blade is not right at each pin, you could crack or break the trim strip.  

Once each trim strip is removed, you will want to pull all the brads through the wood (NOT try to push them back out the way they were originally inserted).  Just grab with pliers and pull.  Some brads MAY remain in the panels themselves, while others may "go" with the strips.

Next, remove all the staples from the bottom and roll the sock off the speaker.  Now, you'll be able to see if the problem is visually obvious.  From that point, a consultation with Magnepan might be your next best bet in terms of advice on how to repair at home.  Could be a case of delamination that may be easily repairable using (and properly applying) the right kind of adhesive.  Also, would ask about cure time for the adhesive, as well as an advice on surface prep.  FYI, there is also some "tape" around the perimeter of speaker that might have come unstuck due to the adhesive aging so check that as well.

As far as re-assembly, the sock is probably the most difficult part (I had ordered new socks in my case--really refreshed the speakers visually). Once that's back on and stapled, you'll replace the trim strips but using NEW holes.  I used a compressor and pneumatic pin nailer which made reinstallation of the trim strips a breeze, with each pin countersunk into the wood a bit.  A bit of color matched fill wax to cover the new pin heads (and fill any holes from the original pins) was all that was left to make them look perfect.