The sound is now consistent and as I said, much LOUDer! No more crackles at all but now I have a buzz that shows up when I turn the Master Volume anywhere from 6 - 10 but goes mostly away at full volume. It also dissipated but is still preset with the Power turned down to 6. With the Power on 6 and the Master Volume on 11, it's less noticeable but dropping the MV down from max even a hair and the buzz/hum comes back pretty hard.
I've tried poking wires and moving things around, also tried changing tubes and all the different settings on the impedance selector but nothing changes it except sweeping the pots. I've also tried a different speaker but it's the same... It's also nothing on the input as the buzz remains with no cable plugged in.
Edit: It's not shown on the schematic, but I went through the build docs again and noticed on page 39 the pic shows a shielded cable from Master Vol to pin 6 of the socket. I replaced the wire I used with some shielded wire and it's now quiet.... well, there's a bit of hum when I'm seated about a foot from the speaker right at ear level, but I suppose that's to be expected