No one messed with the volume setting guys. It was all me.... But, implementing the limiter is a good idea. Also got a cheapo SPL meter and will take some measurements today.
Dave responded as well, and had this to say & ask as next steps:
90mv is a bit high, typically, any DC offset should remain below 50mv. However, 90mv wouldn't be enough to take out both midrange drivers.
Next step is to run the same test, but run it for a while under load with moderate to loud volume to let the amp heat up. With output transistors, sometimes the solder joints breakdown over time such that when they get hot, they expand and those joints fail.