Had another session trying to locate the source of the intermittent cracking noise from the passenger side . Everything on the suspension has been replaced, so I'm ruling that out and it just does it randomly, some roads more than others and only at sub 30mph. It's perfectly fine over speed bumps, but on one residential road in particular which is smooth and flat yet slightly undulating, has the cars rocking front to back a tad and I'll get the cracking a bit more often.
Sounds like it's coming from the cowling at the bottom of the windscreen when you're driving.
So far I've done-
Check around brake disc shields.
Taken plastic cowling off and silicones the clips that go under the glass. One of the drains was completely blocked, so quite handy spotting that.
Given everything in there a good pull and push.
Got the cowling well secured back down with new fir tree screws and the odd dab of silicone sealant.
Spray greased the door hinges which make a similar cracking noise when moving back and forth, maybe they do it when it's closed, wouldn't be surprised.
Had my hand rummaging around the bulkhead for loosities. Put some rubber tubing bits around, but doubt the hoses would move enough on their own to cause the knock.
I've already secured the wheel arch liners.
Glove box seems secure as does pollen filter.
So weather permitting, I'm going to try undoing the droplinks to see if it's the ARB, not that I can feel any play in it. Otherwise it's undertray off and a crow bar.
Failing all that I'm going to get a better stereo because this noise is one of those noises that makes you want to bin the car:
If anyone has any suggestions, which don't involve taking the dash out, crack on.