So I am ready to give one last attempt at this. Since the RCA connections are so crappy, I am thinking of connecting using the speaker level input. Has anyone tried this with a after market HU?

 

Matty_d,
So I redid everything! I rewired from the battery to the amp and the amp to the speakers, re-did the connectors and re-wired the TXO crossovers. I put shorter RCA cables from the HU to the Amp and then wire tied everything up so nothing was "dangling" and putting pressure on the connections.

We just got back from a 1500 mile trip to Maine and back and the set up sounded great till about an hour from home. I started to hear a crackle and pop in the one DDAW on my left hand side. It would drop in and out but the other one was kicking strong and the lowers never skipped a beat.
So I would LOVE to say Im done messing with it but, I cant!
I think I am closer to the issue but, now that this trip is done, I am doubling down to figure it out. If its the speaker, I will get new ones, if its the amp I will send it back to Arc and let them try to resolve it.
If that doesn't work, I own a bunch of guns and a TON of ammo!!

I also put my name in on a "HD employee buy out" on a 2018 Road Glide Special and when I get it I will start from scratch with another system!