Sprocketlabs:
It's been a while since we've chatted about this, but we thought we'd follow up. (We sent an e-mail to you a while back about this, too.)
We have a suggestion for your audio pop issue. We noticed that the pop never occurs when we're using a regular, non-powered speaker box, but it can occur when hooked up to an external amplifier (like you're using). However, we only get the pop when we also have an oscilloscope hooked up to the board. What's happening is that there is a mis-match between the Ground of the PCB (supplied though the USB cable) and the Ground of the oscilloscope probe. While this may not be the same as your configuration, we think it's related to grounding. If you power the Fox Board or Project Board from a battery supply or plug in DC power supply, this might help.
Also, you may want to check out our new
PWM Audio Jack Board
that allows you to hook up Foxonix boards to external speakers or amplifiers. This board has a 3.5mm audio jack, and it scales the output of the Foxonix boards to a level that works for an external amplifier.
We hope this helps!