Ok good, I am on the right track with the hpf up front and leaving the HU flat.
Polarity has been triple checked. I will try what you said about switching the lpf to 50hz and readjusting gain. However, my math gives me 26.83v as my target voltage for the sub.
180w x 4ohm=720
Sq. root =26.83v
Here's my DMM shots for the front 2ch and the sub:
EDIT: Added amp pic.