EXTREMELY concerned about clipping after test tones test??

you'll be suprised at what clips the shiit out of your system
this...i am convinced that some of these bass knobs almost begin to instantly clip the amp. Amps with actual gain knobs are great, but the ones that are any type of "bass db gain" are usually dangerous if you dont understand clipping, and in your case, mechanical limits of your sub.

 
when your speakers/sub starts to sound different, when you turn up your volume/gain, besides just getting louder, youre done.

like audioholic said, you most likely were pushing your sub too hard. when you do, the coil can smack the bottom plate, making a popping noise.

ps, test tones are great to use for setting by ear. it lets you hear the sound nice and clear. use around 50hz for subs, 1k for mids/highs, but remember, any eq boosting could cause clipping sooner, so keep that in mind

 
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