Playing too low of a note for your box would cause mechanical failure of the sub, not a thermal failure like you aparently had.The only realistic way you did that was with too much power.
You thought you'd get around not using bass boost by incorporating it into your gains settings. I guess you calculated wrong. //content.invisioncic.com/y282845/emoticons/wink.gif.608e3ea05f1a9f98611af0861652f8fb.gif Consider this, if you were able to adjust your gains down to account for a bass boost setting, 1) your over-all sound output would be lower, only higher at the boosted freq, and 2) to reach the same output level you would otherwise acheive with no bass boost, you will have incorporated much more distortion into the signal chain than if you had left BB off. No benefit, added distortion. Not a great plan. Short n sweet, leave BB off.
My recommendation, follow the rules. You've been around, Im sure you've read the how-to gain setting tutorial threads on here a million times.... Set gains with h/u at 80-90% of max volume. Nowhere does anybody say turn on bass boost and compensate with gain settings or tone adjustments. Sounds like your settings were all over the place trying to use that bass boost. Stop it! //content.invisioncic.com/y282845/emoticons/wink.gif.608e3ea05f1a9f98611af0861652f8fb.gif Zero your h/u settings properly, turn ff BB, and set your gains. Once the gain(s) is set by ear to have no audible distortion output, THEN start compensating all your system's gain settings to acheive that sound you crave... in your case, overwhelming bass probably... which might mean turning down front stage, rather than trying to artificially boost sub stage.
Hope this helps, and sorry about your sub.
Keep us posted.