@bcwang The best solution to the gain problem is 2 gain modes like the Leckerton UHA-4 has. Firestone also has it on their better DACs.That way if you have high efficiency headphones you can run the DAC in "low gain" mode and it will be much quieter, the volume much less "touchy" and you can use far more of the volume control's range. And those with power hungry cans can run it in "high gain" mode to get enough output voltage for their headphones. It's the best of both worlds and doesn't cost much to add to the design.
The Leckerton is only $40 more than the uDAC-2 and, in addition to 2 gain modes, you get an internal Li-Ion battery for portable use, Linkwitz headphone crossfeed, made in the USA quality, a 2 year warranty, and a really high-end Analog Devices headphone amp running from split +/- 5 volt rails (which give it double the voltage capability, eliminates the need for output and coupling capacitors, and generally enables much lower distortion and better performance). I regret not buying it instead. There's a Head-Fi review on the UHA-4 here:
http://www.head-fi.org/forum/thread/536982/leckerton-audio-slimline-uha-4#post_7240176
And a well done set of measurements posted on the Leckerton UHA-6 that implies Leckerton as a company really knows what they're doing here:
http://www.leckertonaudio.com/2011/01/uha-6s-harmonic-distortion/
And you don't want to just turn the volume to max with the uDAC-2 when using the line outs. Even the line outputs can go into hard clipping with the volume all the way up at. I think around 1 oO'Clock on the uDAC-2 volume control is the most you can use if with the PC volume at max.
And, just to be clear, the uDAC-2 suffers from two very different kinds of clipping (I might need to make this more clear in my blog review):
The first kind is more the normal kind. At some point the headphone (or line) output clips if the
output too high. A lot of headphone amps and DACs clip before full volume. So this part isn't that unusual but it would be nice if it happened at a higher volume setting than 1 O'Clock. That's one reason I suggested less overall gain.
The second kind of clipping is unique (as far as I know) to the uDAC-2 (and perhaps other NuForce products?). It's essentially "internal" clipping of the DAC circuit itself due to the
input signal (via USB) being too high for it. It has nothing to do with the position of the uDAC-2's volume control. Even with it turned almost all the way down so you can barely hear the music, the uDAC-2 will
still clip and distort any peaks that get close to a
digital input level of 0 dBFS from the PC.
If you have your PC volume at full to avoid loss of resolution, and play typical pop music, the peaks may frequently get close to 0 dBFS because pop music is usually mastered that way by design. If you do a straight rip (without volume leveling) from a typical pop CD these peak levels are transferred to the MP3, AAC, FLAC file, or whatever, and the uDAC-2 will clip on them. And some music software has a normalization feature that automatically adjusst the track so the loudest peaks hit 0 dBFS regardless of how the CD was mastered. And, in either case, the uDAC-2 doesn't like those peaks unless you turn down the volume on the PC side which causes the stream to the DAC to no longer be bit accurate and less than full 16 bit resolution.
I hope that helps.