I do have the crossover set at 80 most of the time and the sub is in bypass. The sub apparently has been placed in a position where its giving me more of a good thing than I need. Because of that I've been setting the crossover to 60 when in small and 80 when in large...so your advice to move the sub and check the spl levels makes perfect sense. This obviously is a good example of bad sub placement - thanks for the input