I figured you were doing something wrong, when the gain structure method said get the master meters to just show clipping ..."what were you doing?" That exercise is getting ALL the equipment working in the same voltage range. Otherwise the mixer, the Driverack and the amps could be (as you have found) working in divergent paths.
Now remember.. when setting the limiters I'd like to see you with as much headroom as possible, especially since you are kinda "set it and forget it" It will take a bit of monitoring at first, just try and watch the threshold and gain reduction meters, maybe have someone you trust help, have them tell you what it says, and show them how to set the threshold, and watch it for a couple songs.. so that during normal songs the gain reduction is barely doing anything...
G
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Now remember.. when setting the limiters I'd like to see you with as much headroom as possible, especially since you are kinda "set it and forget it" It will take a bit of monitoring at first, just try and watch the threshold and gain reduction meters, maybe have someone you trust help, have them tell you what it says, and show them how to set the threshold, and watch it for a couple songs.. so that during normal songs the gain reduction is barely doing anything...
G