Also, I don't know how often one actually ever gets full scale output as it is going to depend to a degree on the recordin level, compression, etc.
I've got plenty of albums with really great sound, but are at a pretty low level -- far below the norm. Ry Cooder Vishwan Mohan Bhatt, "A Meeting by the River" is one example off the top of my head.
As for the situation with your dac and the crack, best bet is to just listen to your typical music with your cans of choice and then figure out if padding the input would be a good thing, then you can measure (subjectively as I don't know how you'd measure actualSPL in a headphone), and then refer to PJ's paper on signals and snr in the technical talk area. I'm betting it will still take some trial and error even once you establish a theoretical attenuation value -- but I myself would consider that fun :-).
Can I ask what dac? Sounds like one of the AudioGD dacs to me, or maybe an HRT.
Good luck,
Jim
Jim Rebman -- recovering audiophile
Equitech balanced power; uRendu, USB processor -> Musette DAC -> 5670 tube buffer -> Finale Audio F138 FFX -> Cain and Cain Abbys near-field).
s.e.x. 2.1 under construction. Want list: Stereomour II
All ICs homemade (speaker and power next)