Hello Dave,
I think there is a bit of egg on face happening here

, I decided I would start with a fresh Pi, fresh install on a class 10 SD card just to make sure I had not caused any issues and that there were no hardware issues, powered the pi up and sure enough glitchy video and broken audio. Then the technician in me said "Always check your power supplies first" so I measured the voltage at the GPIO pins and the 5v rail was down to 4.5 and varying. Remove the micro usb power lead and direct powered the project from a bench supply and presto, solid video continuous audio.
Sorry for causing alarm, keep up the great work on this project.
73
Bevan, VK5BD