There is a lot to know about what is going on here. The first thing to know is, as long as everything is set up correctly with the wiring, is the gain settings. When doing this, your deck settings should start all on flat, as any alteration to this, will affect the input voltage to the amplifier. Its like using a test tone to set it from an ipod, but not knowing why the radio sounds so much lower in volume. Same concept. So, best way to do this is with a cd test tone, and not with an external source unless the external source is the main source of music. Make sense?So, setting the actual gains, there are a few ways to do this. I use my O-scope, but if you do not have one, you can effectively use the DMM( to a point of acceptance). The first thing you want to know is the low impedance point of the subsystem, the "tuning" per-say (in a conventional design such as a ported enclosure[bR]). This is the point of maximum excursion within the passband. So, setting the gains at any other position, may cause this to over-excurt the sub and cause distortion, and later on-damage. So, tuning to the max excursion point of the passband is ideal. Lets say it is 44Hz. Then you will want to set the test tone at 44Hz(not the common 50 or 60 that most say-or have said in the past).
You need to know then, the actual voltage, current, and resistance of the setup. This can be done before any setup is required. Using the 44Hz, play the tone at say mid volume, with all gains on the amplifier set on minimum. Now, hook up the DMM and set to VAC. You should know the voltage level that this should be at for maximum output at the subs without distortion(or minimal at the least). You have to calculate for this. You were close on your 34.4V setting if you are getting a real 1200W to a 1Ohm setting. But here is a better way to do it......Take the peak power of the amplifier, and multiply it by 70%(0.7). This is what the amplifier will actually do at peak levels considering the charging system involved(even with the big 3). So, say this amp is rated at 24oowpeak. That would be efficiently 1680W peak. Now, RMS is not always half of this, but lets say for ease, that it is. Actual RMS may be calculated by current, but say we calculate it at .7 again. This would be about 1176watts RMS, close to 1200, but a bit more accurate-generally. So, now we need to figure for resistance. With the subs wired up, but not connected to the amplifier, as this may change the reading a bit, get the actual resistance measured. Lets say you got 0.97Ohms instead of 1 exactly. Then you take Ohms law to get your needed RMS voltage. That would come up to 33.75V@0.97Ohms to get 1176 watts (efficiently).
Now that you know that, you can hook up the subs, turn the tone on at 44Hz, and gradually turn up the volume on the deck(up to 70% of the max volume[this is where I like to use the o-scope, because it can figure for clipping at max HU volume before this is even done]), and monitor the voltage to reach the desired voltage of 33.75V or as close as possible. This will ensure that any other frequency played on that setup will have a voltage less than what is at 44Hz, which causes Ohms law to pass through less current, thus any other frequency played, will not reach the excursion of that 44hz(within the passband-and be careful of "unloading issues" as this is not a part of the tuning process, and deals more with cutoff points and filters and enclosure design control, etc). At that point, you will have the amplifier putting out the best it can for the entire passband for the setup. This can be done to free-air drivers as well before installation to see how much the subs can actually handle...and you will be surprised, if you calculate it correctly, that this can be sometimes, much lower than needed, or expected to power a sub!
i typed this really fast, so please, anyone with corrections, feel free to do so.
Now, as far as the issues, This was explainged a bit in the example. If you are setting the HPF at 55Hz, you change the voltage requirements of the amplifier to produce the output a 1Ohm(or whatever ohms setting you are using). The reason is because of the filter. it will drop the voltage output because it is using the filter to do so. Setting the HPF to 55Hz may be a bit low, especially if you are already utilizing a SSF. You are essentially bandpassing the output, hence the lower output. But this is ok, as long as the filters allow the passband of frequencies to be much broader than what you have set up so far. it seems like you are only allowing maybe less than or equal to an octave, when the output passband can be made much broader than that, up to about an octave and a half. But this also depends on the design you are using as well. I am automatically assuming a conventional Bass-Reflex design as an example.
Set the HPF higher than 55Hz, most set it at like 80Hz or 120Hz or so. You should get much better output that way. The HPF says it is allowing higher frequencies to pass through, and attenuated the lower ones. So, setting it low, will result in bass frequencies suffering, hence lower voltage.
As far as not moving much from 14.1, that is awesome, but check the voltage drop by adding other components as well, and also with the vehicle off. Read it palying before everything else is turned on, then turn on the ac, door lights, rear view mirror lights, cycle the ac within the car by closing the vents, etc. Then check voltage. if it only drops about .1-.3 at the most, that is good. Hope that helps. And please, if anyone sees an error here, correct it righ taway. i typed it very fast and im not sure what flow i was on when I typed it. I have a lot on my mind right now, lol. Thanks guys.