well so far i have checked the amp with a DMM. car idling no music gives 13.8. turning the volume up to the point i start hearing the distortion/clipping the clip light on the amp does come on and voltage i have seen drop to 11.6 volts. the reason my gain is up 3/4 way is due to 2v preouts. i need to find out why i am losing voltage and if thats the problem or not. Should i still make the box smaller? ID says not too. but it sounds like i got 1 8 in the car and then bam its clipping all to hell. what do i do? even songs that wang really hard like prodigy's narayan just sound like im running 1 8 and i cant go louder because its clipping like crazy.
Try this.. use a cd player .. using a sterio head phone jack -> RCA converter .. run the cd player (or any audio output device even MP3 player etc that has headphones output on it) and listen to your subwoofer.
If it sounds really nice and clean, you might want to look into your head units RCA output, maybe your head unit is going bad\out. IT happens to brand new equipment all the time. If you find what I said to be true, swap RCA's from the HU to the AMP if still same prob -> bad head unit.
This will isolate the amp to a new signal source. Turn the gain all the way down, and start from there.
Im pushing more RMS than you are, and my alternators not as big, the only thing that happened when my system did draw to much was the lights dimm, voltage dropped down to 12.4 volts. I was almost ready to sell my ORION HCCA 250, I added an extra battery which helped tremendously but it still got hot after its sucked that battery dry and cut off, I added a capacitor and lifes been great ever since.
For now though.. You need to see if your amplifier is going wack, or if the signal from the HU is a possible problem. Ive seen some weird shit with head units dissapointing new subwoofer setups and all along is was the RCA output from the head unit.
try what I said with the cdplayer \ mp3 player as an input source. If you still get the same problem with the sound , then try a new amplifier.. shit.. go to wal-mart buy an amplifier .. test the subwoofer out if it works then you got a bad amp, if it doesnt .. you can always take anything back to walmart and get your money back LOL .. Fkn love wal-marts customer service policy.