When I hear that popping noise, I know to change my needle. It's not sharp. It only takes one time of hitting face plate, which is probably what is happening. The heavy fabric can "pull" the needle past the needle hole, causing the needle to hit metal. Then it is ruined and the popping sound starts. Maybe try a 90 or 100 size needle to sew and slow down your stitching. The needle has a lot of work to do. This is what I learned when making a blue jean quilt.