Hey CHOPPER74,
I know of a bose set with the same crackling problem. When you sent them back did they replace or repair? I'm suspecting a fatigue crack in the wire where it runs throught the clamp above the earpiece.
L'WAAPAM,
I have used both the bose and the DC. On a big day I must say the bose wins hands down, it's a lot lighter and more comfortable. Yes the DC's are more robust but why don't you just take a little care when handling them? Carry a spare set of batteries and you needn't worry about the benefits of passive noise reduction. There are things that could use a little improvement on the bose such as a better latch to set the length and more gentle cable clips along the headband but overall I reckon the bose is a much better bet.
Happy flying whatever you choose!