I'm using an ES1989 (I think. I can check when I get home. It's an ESS something close to that) . Don't you have to load a mixer/volume program prior to running DOSCab? I do anyway. You can set the volume and a few other settings in there. I'm using an external AMP in my box. I initially set the volume down a bit (as I recall) so it starts up at a mid level and not full on. Part of that is set in DOSCab, the other I think is in the mixer. Then I set the AMP's volume to avoid distortion. Since you get the same results from 2 different cards, maybe the volumes are just set too high. Once it's running, I can use DOSCab to adjust the volume up and down. I'm pretty sure there is a fixed / adjustable setting in jukebox.ini or one of those files as well.