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What are you using for a soundcard? ISA or PCI BUS? How many programs are running in your SYSTRAY? Sounds like there's a process interrupting the data. What is the sample rate of the sound you are playing? Thanks.

I haven't made one personally, but I think you can find them in the Global Computer products catalog pre-made. The only thing of concern after enclosing the box in a box would be cooling. It wouldn't take long for a sound (and heat) insulated box to warm up. Detrimental to hard drives, CPU...