Cracking/Popping sound from Jeff Bagby's Baby Boomer

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I bought a Baby Boomer Subwoofer kit from Meniscus with the PR option ( Baby Boomer ). I have constructed the cabinet exactly according to the build plan.

MDF is 3/4 inch all side except the front baffle is 1" (two 1/2 inch MDF glued togather). Inner dimension of the driver chamber is 10.5 sq inch and Plate Amp is put into a separate chamber and the wire hole is sealed properly. Top, back and the bottom of the driver cabinet is wrapped with supplied wedged foam.

When I first time connected the Sub and played a deep bass test tone, I found that the one of the PR making very odd rattling sound. I opened those again and found that the extra weight in the PR is loose and tightened both the PR weight and that rattling sound is gone. But, now when I increase the volume a little, there is a cracking sound from the PR and may be from the Subwoofer driver. It seem that the speaker can't take the load, but the sound is not high at all or the sub volume is not much, it is less then 1/4 of the volume. I thought that may be as it is placed on the floor and it happening due to the vibration with the floor. I stood up on the cabinet to reduce the shake and I understood that it is not happening due to the vibration, it is probably due to the PR. I have tested with my 2nd Sub (Yamaha SW160) and it does not make such sound. I opened the divers and found no physical damage anywhere.

The kit contains Dayton 1 x DCS255-4, 10" Woofer, 1 x SD300, 300W sub amp, 2 x Dayton Audio SD270-PR 10" Passive Radiator

A video of the sound is attached herewith https://drive.google.com/open?id=0B8LbKgJRfv4nQ0RhazRNOGZqY2s

Can someone suggest and help me out please.
 
Hi daniel4381,

Could be you are asking to much of the little 10"driver?

Your video shows a heavily overdriven woofer, and a passive radiator which is not moving.

A PR subwoofer is still a vented box, and needs a HP filter (high pass or low cut). In this case it should be part of the recommended amplifier, about 30Hz/2nd order HP according to posts by Jeff Bagby in the PE Forum: Yung SD300 subsonic filter? - Techtalk Speaker Building, Audio, Video Discussion Forum

Regards,
 
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