hes right..... IMO your amp settings are high because your tryign to make the amp put out power it isnt taking in. That amp with a solid electrical will give you the results that aparently are pretty **** decent from what i hear. make sure it's the pro and not the pzi series. Typically the amp would drain you weak electrical..... usually it just pulls that current until the electrical blows or the amp blows...
reason your voltage drop isnt so bad is because of that amp cant pull the power with that bad ground. scrap that paint man. you want clean barely metal for those terminals. 220amp alt and 2400 in the trunk will be MUCH better for that amp. After you get that alt, the more batteries the better, the more wire the better. get some wood glue and glue that terminal back in there and make sur eit has a good seal. btw what kind of car is this in?
does your HU have a subwoofer level or just bass/mid/trebble? Set you HU at 85% ish volume. Use a 50Hz tone and slowly turn the gain up. as you turn the gain up the thje loudness will plateau, beyound this point it doesnt get much louder and it will distort. you have to find this point to where the sub plays as loud and clear as possible. the sound differance at this plateau is hard to hear. you'll hit this point of most clear bass when you look at how loud it gets vs how much you turn the gain knob. at some point the increase of loudness per amount gain knob increase will drop off. you can hear it in the subs as you continue to turn it up past this point/plateau as the cones do not move as fluidly and efficently.
to answer your other question.....when you clip it it seems to be a little louder, but only by a barely audible amount. Even then it sounds like shit and blows the subs. with a clean signal it wont seem as loud, but once you give that amp the juice it needs...........it'll get loud.