Bigbannana,
Did you get a chance to see (feel?) if the THA was overly warm?
Could it have been thermal protection shutting the amp down - I understand why you've done it, but having the amp sandwiched between what is essentially two bits of carpet can't be doing much for its cooling?
I used to come across this when friends woud install amps upside down onto parcel/stealth shelves, not realising the heat sinks of their amps wouldn't work upside down.
It;s such a shame you've had anightmare from beginning to end with this 'upgrade' (I'll surround the word in inverted commas, so as not to offend!)
Selfishly I'm hoping you've just got a duff amplifier, or the currently less than ideal is adversly affecting it, because I really want the 5 channel/component upgrade/Earthquake sub upgrade to sound as good as I hope it will, yet be as reliable as a factory install.
Think I need to get together with Gizee and take him up on his offer of a listen...
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Gone but not forgotten:
325i M Sport (E92), Black Sapphire, Coral Red Dakota, 19" 225's, Seat Heating, 6FL and de-badge
Replaced by 6.2 litres of AMG powered C class.
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