The D250 being able to reach lower should be a better match for your 15's, just choose a horn that can function effectively down to 1khz. There isn't much if any useful content from a bass above 6 or 8 khz anyway. Could cross them around 1khz and not have any holes in the sound off axis.
I've had pretty good luck with plastic horns but I don't abuse my equipment. I did have one crack in a vocal wedge. It does make me a little nervous sometimes knowing there's a driver hanging out on the back end of a plastic horn though, so I'm a little more careful with those cabs. Aluminum does make more sense to me for road worthy gear. At least for piece of mind. Thousands of cabs have plastic horns and do OK though.
I've had pretty good luck with plastic horns but I don't abuse my equipment. I did have one crack in a vocal wedge. It does make me a little nervous sometimes knowing there's a driver hanging out on the back end of a plastic horn though, so I'm a little more careful with those cabs. Aluminum does make more sense to me for road worthy gear. At least for piece of mind. Thousands of cabs have plastic horns and do OK though.