1) The holes that the tie rods fit into are supose to be tappered for a tight fit, if you drilled them with out a "reaming bit" that cuts a tappered hole they are most likly moving around under the load of your 2700 lb car....
2) Your popping noise is most likley a loose spring purch, check and see if they are all tight.
3) I had a strange thunking noise that took me a month to find, it was a loose swaybar end link. It was only loose by like 3 turns but there was a huge amount of noise...so check them to.
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