Project issue: output power of a Class-D 2*100W

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I'm working on a 2*100W Class D amplifier DIY project and got some problems.
I've tested it with a 1kHz sine wave input as well as some musics.
It started to distort with a 11V RMS output(30W@4ohm). This is far away from the 75W@1% THD which mentioned in the datasheet of the chip.
At the same time, the output inductors on board began to make noises which would raise up when I increased the output power.
If speakers are connected, I could hear pops from it.

Does anyone have any ideas about the issue? Thanks a mmmmmmillion!
 
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