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@hippy
Are you greasy everything when you refit it?
Are you tightening stuff correctly?
If you lean on the crank whilst off the bike can you make it make the noise? It's easier to track down while there's no road buzz.. got a stand to sit the bike on? Does it only happen when applying lots of pressure to pedals or can you get it just spinning the cranks? How's your chainline? Did you try a different chain? It still sounds like a bb, crank or chainring thing to me..