Then it’s not the output tubes.
The Hotrod and Blues Deluxe amps are notorious for faults from poor design, including general stuff other posters have mentioned, as well as problems with the low voltage power rail that powers the transistor/op amp circuits and the relays, which when it fails can cause parts damage that results in all sorts of noise getting into the signal path. The 5W cement resistors in this circuit are mounted right up against the main board and eventually overheat and charr the board, nearby traces and other parts. If you see charring around those, start there.
Popping noises can also be from bad connections, cold solder joints, broken jumper cables and oxidisation on ‘slide-on’ terminal connectors, FX jacks, or loose tube socket pin clamps. Chop-sticking can reveal where loose joints are.
[/quote]
In all fairness the last two I looked at had bad output tubes also. They both were the newer design with through hole plated boards and factory tubes. I am just now seeing these newer ones like this and only the blues deluxe. Yes they are through hole plated. Fixed one set of problems and created a new one. They did lift the 470ohm resistors off the board on these, but there was still some discoloration so I did the updates as usual. The ribbons snap RIGHT OFF like a potato chip! If it is setting at 15 ma its likely the tubes are bad as well, just not the source of the crackling. Has anybody else worked on the new boards that are through hole plated? Heads up if not! Also solder wick takes forever to desolder these. Best to get a pump!