Just had a customer send me this. If you skip to 30 seconds in, you’ll hear it:
Now I’ve had crackles accompanying very high levels, like accent swings, and I’ve known low battery to cause problems, and sometimes SD card (all of which we’ve now checked), but I haven’t seen it happen in simple font idents with loads of headroom and no ultra-low frequencies, that only peak at around -12 dB, and I haven’t known crackling to continue when no sound is being played at all.
The board is a 2.2 from KR, so all reputable, but of course Sod’s law is that the hilt is in the USA and I’m in the UK. Hence before I put the guy to the hassle of international shipping, I thought I’d ask you guys if you’ve seen this before. If we’re confident it’s just the speaker, it might be quicker and easier for me to pay a USA based installer to swap it out, but anything more than that, like audio amplifier system, then I would want to look into it myself.
Any thoughts welcome.
What does serial Monitor say while that’s happening?
Audio Underflows?
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I was trying to talk the guy through various tests, but Arduino was a step too far.
However I think we’ve partially resolved it. Turns out hsi battery wasn’t as charged as we thought, and now that it is, everything works better - except bizarrely for that one battery level indicator sound font, which still plays up on the font ident. The only error I’ve found in the config is that I’d set the Bluetooth module to power from an LED pad, but on that battery level font, instaed of habing StylePtr(), I have &style_charging. But in theory it shouldn’t make difference I wouldn’t have thought - the LED pads are on or off, so maybe that’s a red herring.
Anyway he’s happy enough now that the main stuff works right. When I get a sec, I’ll load up his exact config onto an identically-wired hilt and see if I can recreate it.
Will report back. 
That’s not actually true, in a lot of senses, but I don’t think that’s relevant to your issue here, so I digress…
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