clipping?

Only true way is to use an Oscilloscope.

But, I'm going to assume you don't have one laying around, nore the $1000+ to buy one.

You can do it by ear.

Play a test tone.

Set gain Minumum, slowly turn it up, there will be a point where it doesn't get any louder and starts sounding a little weird, that is clipping. A few notches before that and you will be fine.

 
no more than 3/4 for sure.
No.

just an estimate how far do you think i will be from maxed out with out clipping im about half right now
It depends on too many things. 1/2 way may be too much or too little. The gain adjustment does not go from 0 to 100% power output. It is used to match the input sensitivity and that's it. If your headunit has a very low output voltage, you may need to drive the gain pretty high. This may cause noise from the amp but it's not likely to be too audible if it's just on the sub.

 
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