The ceramic insulators are supposed to contain aluminum oxide to overcome the heat conduction issue. The working channel actually got the heatsink very hot very quickly. On par if not better than the pads that come with the kit. If they insulate the transistor too much - I'll learn the hard way.
I have to look for a unique angled standoff to get one of the smaller boards installed and stable. Currently its just floating in there and its not good at all. So I may just order a few Fairchild TIP50 from mouser while I'm at it. If that doesn't work then I'll ring up the queen and order the whole board.
Paul, can I mix and match with this part?
http://ca.mouser.com/Search/ProductDetail.aspx?R=TIP50virtualkey51210000virtualkey512-TIP50Not certain where you guys source your parts. Its funny how many other Crack/Speedball parts come up as suggested by others who shop at mouser.
Re LEDs:
I found my meter did not provide enough current/volage to light them up enough to see with the light on. Getting it dark enough in the room prevented probes to be used....
Eventually I figured out I can just use a 9V battery with a 220ohm resistor in series with test leads to light them up properly. Found a bad LED on the bad channel side. Curiously was an issue with one of the smaller plate boards early on and triggered similar crackling... followed by a gigantic SNAP in the one channel. I have a feeling its the root cause here because its so similar to the previous crackling issue.