To me, the jetting looks right... then again, you're talkin to the guy who has battled his share of demons with it as well, so by all means am I the expert!

When you put your new muffler on, did you use a new gasket at that connection?
Here's my opinion, and it's just that -- an opinion. The more open the muffler is that you install, the more difficult it is to chase all the pops away because of the lack of backpressure.
I had a MAC on mine, and no matter what I did I couldn't get them all gone. When I put the Dyna muffler on, that task was made easier by at least tenfold because (I believe) of the increased backpressure the Dyna muffler provides.
Like I said, that is just my theory, but I truly believe there is something to it. IMHO, the more open the pipe, the more important fine tuning becomes, and the harder it becomes.