Much testing over the past day. Comparing my large condenser to small condenser, the large condenser provides a bit better noise floor, but not as much as I was hoping for. Primary driving factor for noise floor is any background noise. I don't have an anechoic chamber or a sound insulated theatre room, so any noise from kitchen fridge, car driving by the house, dog walking around, etc. has potential to contaminate the noise floor and greater impact than the mic alone. I am generally only taking two measurements in a row now for confirmation, if they both match then delete one.
It's staggering to compare the noise floor of 5.5s sine sweep, to 5-15s of FSAF measurement. The bottom traces are the sweep noise floor, a good 20-30dB lower.
With a small 120mm driver like Wavecor WF120BD03, there is a huge difference with LR2 HP at 20Hz, vs at 300Hz. It is broad spectrum overall TD difference, so the TD vs frequency doesn't give many hints on the cause of the distortion.
The following tests were completed at a level of 83dB/1m, with mic placed at 315mm, so about 93dB presented at the mic.
Here's with HP at 20Hz:
...and here's with HP at 300Hz:
These were tested with real music, a "pop" track, showing 15.6dB crest factor, and the sample includes clipping (thanks music industry), however a wide spectrum of excitation for this sample. Listening to the residual has the obvious "crackling" distortion in the full range sample, and much much less so with a high pass in place.
I then added a low pass filter instead, at 500Hz, and played the same track with HP at 20Hz. Simply adding the low pass gets rid of the crackling, the high frequency products are now absent despite the driver producing the same bass output.
I completed a lot of other measurements with and without passive filter components in place to confirm, but not easily presented to an online forum. The above detail should be enough to indicate that the "secret" to a low FSAF result is simply a multi-way speaker. 3-way to separate bass and midrange - high frequencies will reduce the modulated distortion products created by a woofer greatly.