That is good news, Glad you got it sorted, I did say it's going to be something simple, sounds like different tolerances on the two sprockets causing the issue with chain. Thinking about it, I have a vague memory of something similar on one of my bikes in the long distance past that required a swap out of poorly machined parts, I don't recall the noise you describe but the solution was replace with a different sprocket to cure the problem.
and well done for coming back with the end result. All too often there are multiple posts that remain unfinished with no conclusion or report back.
I've given you another like on your last post there to help put you on the leaderboard.