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Second round of prototypes are done at the factory; I have a 3rd round in the works as well for testing comparison purposes :

So I gotta rip my HU out and disconnect the speakers first? You don't have to but if you don't, you get what you got. And when you're running on head unit power, you should never (in my experience) be at 80% volume. Every head unit amp I've tested distorts at ~60-65%.

so you are powering speaker with the headunit? I have seen this issue and have dealt with it. The right way is yes, unhook speakers and test the h/u speaker outputs and use the volume from track 1 and 2 as your max and match your amp to that before you hook up your speakers again. you may end up with the gain all the way up since h/u internal amps are pretty dirty.

Don't use the dd-1 with speakers hooked up. Although you can do it that way you shouldn't.

maybe you didnt plug the rca in far enough. It a common issue people have for some reason. Some rca's have thick boots that keep them from plugging in all the way i think.

Coming from someone that talks about max rating of his subs, learn something before giving advice. Yes Rockford puts out more then rated but not 50% more. The t1500.1bdcp for example is at most 300-400 watts less then what the birtsheet says. Birtsheet mean nothing in the real world. That's on a resistive load with optimal power supply. In a car you have impedance rise, music (dynamic), voltage drop, ect ect... Or we could all live in fantasy land and believe max power ratings.

Everyone is gonna become mazda2442 now..