Egodriver popping

[add4]

Just mounted my egodriver pcb into a box. It wasn't popping with my test box (simple box with one 3PDT, one LED, and 2 jacks, i use connectors to test the circuits before boxing). In the test rig, switching it off and on didn't popped.
I now put it into a box, and used a small pcb i made for the switch wiring and it pops really loudly when turned on and off..
i guess it doesn't come from the circuit, but from the LED then, is it possible?
do you have solutions for that?
i'm trying AMZ's trick of sticking a capacitor between the LED legs, it helped me before, but so far no luck.

any help is appreciated :p

[add4]

and before someone asks, yes, i put R1 into the board even if it's mentioned as optional..

[jkokura]

It sounds like either you have a cold joint on your switch, or simply a bad switch.

Jacob