I recently built a bottlehead crack amp and got a problem similair to yours, however I fixed it by just wiggling the tubes back an forth and also by taking them out and putting them back in. I got a tip that using a chop stick or any other nonconducting rod and poking around inside the amp on the connections, if you can provoke the crackling sound that way then you know a connection is bad. Maybe this will help otherwise I don't know.
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Here's something interesting, it happened again just a few minutes ago, and this time I let it crackle and restarted my computer, on restart it worked fine, without even touching the amp. This leads me to believe it's something to do with windows, as it never happens in Linux. Any ideas if this is the case, it almost always happens while I'm playing some sort of video game.
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There is the odd occasion when I get static distortion coming from certain music files. One of my HD albums is unbearable because of the white noise it produces.... maybe some tube amps are just picky with new technology!
Also if it was your tubes, I think the effect would be more subtle and gradually get worse, not bombard you instantly.
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