The woofer connections from the original amp guts to the small board you see there indeed have two pins per woofer. The wire gauge for the woofers is 16ga in the car. The rest is about 20ga. Since the woofers get more power, they get heavier gauge wire and their pins on the connector are bigger as well. They are a blade vs a pin. So, I ran two wires from my terminal strip to double up on the gauge just as the original amp did. Before I put everything back into the equipment rack I'll take a good picture of the amp-side connector so you can see what I mean......a question....why are you using two wires per connection on your terminal block to circuit board wireing (right and left woofers it looks like)...and why are there 16 solder points on the board for 4 sets of speaker wires?
So, my balance and fade issue has been resolved by reinstalling the LOC between the harness and my amp. A lot of hiss is gone too. It's ugly looking, but has level controls on it, so I can tune out the noise in time. One big problem solved.
I have done quite a bit of listening with various source material and I have found some songs go way deep and thump the front seats with the fader all the way forward (no sub). Some others not so much.
I corresponded with Scott Buwalda, founder of Hybrid Audio Technologies, who reviewed my build log and pictures and he suggested I may have a "tunnel effect" going on with my speaker mounts. Usually you would chamfer the rear of the baffle so it gets wider from front to back and this allows the woofer to see more air behind it. I didn't see how I was going to accomplish this with my mounts because my rings are only 1/2" wide and chamfering over a 2" thickness would leave nothing to glue the rings to. But, maybe there's a way for me to re-do the mounts so I have a single 3/4" thick ring to mount the woofer to, but work something else out so I can have a bigger hole and no tunnel behind the speaker to allow more air space behind the big-ass magnet. Scott has a valid point and if these midbass drivers perform as well as they do with little air space, opening it up should get much more out of them.
I'm hoping to meet up with dummptyhummpty this weekend when he's up here in the Bay Area and compare my system to his. We used the same speakers and brand of amps, but his woofers are mounted to the door card. This would give me a good comparison at least to see if all my door work was worth it.
I played around with woofer phase again and can't see much difference with one out of phase. I did reverse the phase on both tweeters and they seem much less bright. I have to get some good sampler music to CD and do some driving around and more listening. In the garage with the engine off I can tune things to get good sound on most source, but that's in a quiet environment.
Depending on where I get with the door stuff, I may visit a shop and have them critique the SQ. I know no one else locally who has gone to this level with updates, so it's hard for me to know if I'm expecting too much or not. Hearing a tuned system will help, but also having someone with a tuned ear listening to mine would help identify the problems.
Thanks for the advice guys! You've been very helpful!