Thanks loads for your help! I'm getting there! :-)
To simplify things i'm ignoring the whole serial/parallel config of my 4speakers->2 channels and i'm just working with one speaker.
20W rated speaker, measured at 4 and a bit ohms by my voltmeter. I'm struggling to find specs online, so i'm presuming that they are 4ohm speakers.
Firstly, why do you say put your stereo at 3/4, why not full? If that's the maximum?
Anyway, i'm turned my gain to give Sqr(80)=8.95V across the speaker when playing a 1khz tone in XP, and I still have crackling when no music playing....
The thing I don't get is it seems to be signal-dependant, in that when I move the mouse, the crackling intensifies. However the headunit doesn't pick this up at all. That would lead me to believe the usb cable for the mouse is interfering with the amp, and not the headunit. But the headunit is wired very similarly near the amp, and with much smaller, worse wires. (Headunit using a cassette-mp3 adapter).
This is all running from an external sound card, which is a bit rubbish, and could be the problem, but then again why does the headunit not have a problem?
I suspect the next thing would be to move the usb cables around, but that's a right pain
Help appreciated!
Thanks loads