I figured out what the popping is, but can't figure out how to fix it. When the battery is connected, the voltage jumps to about 1.5VDC, then slowly back down to about .25 to .5 volts. This causes the cone on the headphone to stay pushed out a bit, and when the volume is turned up, the cone hits into the plastic enclosure. I have a 1000uf 15V cap on the L and R output, and a 10uf 50V cap on the L and R input. I have already checked for polarity, and it is correct. Is there a way to prevent this voltage from the headphone? Also, one more thing, when power is disconnected, the voltage comes down to about -3VDC, and stays there (with no headphones attached, just a multimeter) That causes the headphone, when it is connected to pull in a lot, and produce a loud clicking noise. Does anybody know the possible cause for this voltage?
Other than that, it sounds great.
Thanks for all the help, Mike