Loud POP when engaging stomp switches

[banjerpickin]

Hey there sports fans, I recently completed a build where I jammed two independent Tubescreamer boards into a single 1590BB enclosure for a friend, much like a King of Tone.  Yes, it is as mid-humpy as you can imagine.  Sort of the Court Jester of Tone, perhaps 

Anyway, I used Aion boards which have 1M Ohm pull-down resistors on the board already, and I've never had an issue with popping when building them.  The documentation notes you can go up to a 2.2M resistor, but I've always used 1M: 

https://aionelectronics.com/wp-content/uploads/2013/11/aion-stratus-ts9-documentation-v2.pdf

The only modification I made is there are 2 status LEDs in series per board instead of the usual 1.  I had to move the holes for the jacks to top mount after I got started, and decided to fill the original holes with another status LED to seal up the enclosure (and because, let's face it, Rock N Roll). 

At first, the pedal worked fine with no popping.  However, I noticed that when inserted the cable plug was brushing up against the LEDR 4.7K resistors at the top of each board and might strip off the outer coating over time.  I decided to move them to the underside of the boards where there was still room between the pots.  I disassembled the pedal and moved the 4.7Ks to the undersides, but when I reassembled BOTH sides began popping.  REALLY loud.  There is no way the 4.7K's are grounding out, and the LEDs are still working fine/same brightness.  What gives?  Any ideas on what I might have adjusted?  Otherwise the pedal continues to function great. 

I have built other double Aion board pedals (TS and OCD, for example), and never had issue with popping powering them off a single 9V plug/power source.  The only difference is, they didn't have 2 LEDs per board and the 4.7k wasn't on the underside. 

Thank you!   

[Kipper4]

It might just be that the anti pop resistor(s) have come loose (intermittant) when you ammended the board.
Wierd how it worked fine before but not now.

Did you chain in another pedal?

Rich

[banjerpickin]

It might just be that the anti pop resistor(s) have come loose (intermittant) when you ammended the board.
Wierd how it worked fine before but not now.

Did you chain in another pedal?

Rich

Seems crazy, but I guess I better go check all of the joints.  And no, it was the only pedal in the chain.  Another pedal I was testing worked just fine before it, so can't be the guitar or the amp.  This seems absolutely BONKERS but I wonder if somehow the the plug from the cable was grounding something out either through pressure, contact, who knows.  Now that they aren't applying that pressure, the POP has begun it's reign of terror.  That really seems like it's the only variable that's changed!  Utter madness.

Hope I don't have to disassemble this thing again, it's quite the undertaking.  Thanks as always for your input, Kipper.

[Kipper4]

Talking of sport.
Anyone see what Dave Ryding did?

Fear not here's a page.


http://www.bbc.co.uk/sport/winter-sports/38710917