Need help tuning amp & new sub..Smoke involved :P

[TrippiN]

So first off, just bought the subs last week, and finally got a chance to put them in my brothers car. I was running (2) of them @ 2ohms in a single chamber 3.5cuft sealed box all week (was waiting to build a new box). I just got around to building the box this weekend, got it all designed and built for (1) sub. And was playing a 32hz test tone with gains @ ~33.5-35.3volts (erm think i was reading it right..) Figured Square root of 1200w x 1ohm is 34.64v so was told to tune to that by some various internet sources. Anyways, had it all hooked up, played the tone, started adjusting by ear (guess this was bad) smoke started rolling out of the port. Immediately turned it down, powered it off, took the sub out, checked the coils, everthing looked good, just stunk of burning plastic or glue... So could this have just been having the gains too high/no damage to sub.. or am I screwed?. I have since that moment, let everything cool, backed down the gains to the 33.5-35.3, turned down the bass boost, EQ is flat, and everything plays fine.

So am I lucky, just breaking it in, burning some glue/insullation? Or lost cause/screwed?

Box: 1.5cuft slot ported to 32hz thanks to RF box wizard/RE Port wizard/Sketchup

Manufacturer recommends 1.5ft3/2ft3 ported

Amp: Power Acoustik D1-2000D

- 4 ohms: 600 watts x 1 chan

- 2 ohms: 900 watts x 1 chan

- 1 ohm: 1,200 watts x 1 chan

Subwoofer: Power Acoustik 12" PW3 Dual 2ohm

Peak: 2600 watts

RMS: 1000 watts

Car: 2011 Ford Fusion

HU: Stock MS Sync HU

Wiring: 4ga pos/neg Knukoncetpz kollosus / 12ga subwoofer kollosus

Subwoofer is wired @ 1ohm. Pos to pos to amp, neg to neg to amp.

Edit:

So realized what I had done wrong, kinda went newb on the tuning. Went back and backed everything down, disconnected sub, played a test tone, set my gains @ ~34-35v, connected the sub, then played some music, set my subsonic and low, then barely touched the bass boost. It sounds good and all for a single sub in the enclosure, but even after the tuning the amp and sub runs hot. The sub is hot to the touch immediately after, the cap is super hot.

I was running (2) old 2006 Pioneer TS-W256C (400wrms/800peak), and amp never got warm, subs took it like a champ on the same amp. And the (1) PW3 feels to the point of fire, and amp running warm even with 10 minutes of bumping.

So question being, is there anything that I am doing wrong, sub just breaking in, or should I be worried about the sub. Just looking for tips/guidance.