Thanks Richard,
your advice is, as ever, well informed sagely and intelligent. I 
suspect that I'm not going to find a definitives answer here, but for 
your interest, and for anyone else who may be interested, I've posted 
a 10sec  (wav) clip of the kind of crackle I'm hearing. this sort of 
thing will continue through the full length of the recording and can 
be heard when the tape is played back using multiple recorders, all of 
which have been tested using other tapes, which exhibit no such problems.
http://www.mikehirst.netfirms.com/audio/rhclick.wav
filesize= 1392640 byte(s)
riffsize= 1764036 byte(s)
format  = Straight-PCM
channel = 2
depth   = 16 bit(s)
blk.size= 4 byte(s)
smp.rate= 44100 Hz
samples = 441000
playtime= 0:10.010
you will note from the clip that the crackle can only be heard in the 
rh channel. this is typical of the phenomenon, but it can sometimes be 
heard in both channels (with a bias towards the rh ch).
I have experimented with some of the de-crackle filters I use when 
working with disc transfers and as Richard suggests, the crackle can 
be removed, I am however curious as to where the crackle comes from.
Richard L. Hess wrote:
Hello, Mike,
Tom Fine has already posted a number of good explanations.
There are, however, less-common explanations that you may wish to be 
aware of, just in case.
(1) If there is a mismatch between the record machine record and 
erase head track position, perturbations in the record bias and/or 
erase MAY print to a tape like this. DC-(i.e. permanent magnet) erase 
may also cause something like this, but it is usually more of a 
"burbling" or what is sometimes called "rocks".
(2) Static electricity and PLAYBACK machine "glitches" CAN print to a 
tape without the recorder being in record mode. It's uncommon 
(thankfully),  but it can happen. Static can be generated by fast 
winding in a very dry environment, and depends on cassette materials 
including the shell and slip sheets. This is more prevalent with 
reels than cassettes.
This clicks can usually be removed (depending on their source) by a 
declick/decrackle plug-in for your favourite DAW. The Magix 
restoration tools version of this is the best I've yet owned, but I 
haven't owned either DC7 nor the high-end Algorithmix version.
At 08:53 AM 2008-09-18, Mike Hirst
Here's a thing that's been confusing me for some time. I have spent 
the past six months working my way through a large number of 
cassette tapes mostly recorded between 1985 and 1995. every now and 
again I notice light, but significant crackling. This is often more 
noticeable in the right channel, but not exclusively so. On some 
recordings this is louder, on most recordings this is not evident at 
all. This is not restricted to any one brand of cassette, nor is it 
associated with any one playback machine and/or soundcard. Can 
anyone explain this for me?
Richard L. Hess                   email: richard@xxxxxxxxxxxxxxx
Aurora, Ontario, Canada       (905) 713 6733     1-877-TAPE-FIX
Detailed contact information: 
http://www.richardhess.com/tape/contact.htm
Quality tape transfers -- even from hard-to-play tapes.