I brought the computer home after the show and spent all day trying different things. I bought two different USB audio devices locally and both of them had even worse pops than my device. I tried tinkering with buffer sizes, measuring latency (http://www.thesycon.de/deu/latency_check.shtml), different USB ports, disabling everything that I could think of -- nothing worked.
I came across one posting in a computer audio forum (can't remember which one) that I discounted at first but when things got desperate, I tried it: Connect the USB audio device to the computer through a USB hub. I tried it and it worked. No popping, no clicking. Strange.
What do we learn from this?
1) Never put 32-bit Windows 7 on a laptop with no Windows 7 drivers (I ran great until opening night -- what changed? I have no idea) -- the M65 has no Win7 drivers for it.
2) In the show notes for the board operator, remind them to go to Sound in the control panel and make sure that the Default Output is the one you want it to be -- Win7 will change these things randomly and for no apparent reason.
3) Once you settle on a USB port for your output device on your computer, stick with it. This may be superstition but I think Win7 changes settings just to mess with you

I'm still going to replace my Link.USB (it's USB 1.1 for goodness sake) with a Behringer FCA610 but I will either get proper Win7-capable computer or re-image the existing one with WinXP.
Live and Learn.
--Jeff
Mainstage Irving-Las Colinas