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ICQ>
Just on the odd chance you haven't considered this possibility, some older stereo speaker setups had a floating ground to the chasis. Thus each speaker was only connected to the amp/head by one wire, the positive lead. Hopefully when you put in your after market system you make sure to run a pos and neg lead for each channel. If you used the oem wires, and they used th two wire system, perhaps some of the insulation has worn off/cracked at the flex points (door hinges).
Either of these scenarios would make the system succeptable to any variety of static electric discharge, or ignition noise. You might peruse Crutchfield's page (http://www.crutchfield.com), they have D.C.-line noise supressor you could try putting in front of your head/amp's power supply to see if you have developed a noisy source. I think it is like $15.
Since you said you tried pulling the head and the speakers still pop, I would see if one of the coil leads for the speaker are touching the chassis/door. You might also try insulating the entire speaker housing.
Just my two cents
Jonathan E. Schneeweis
1989 245DL 102K Blaupunkt Reno w/10 disc changer & Pioneer TSA-1086's
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