...or the frame is slightly cracked?
I don't think so, tomorrow I am going to clean it and give it a good once over, pull the b/b, again, and try with a new(er) one. It only happerns when the left crank hits th 5-7 o'clock positions on rotation. They are older cranks I bought on CL a few years ago so the square might be off abit and check for a crack in the arm as well. Last time I was riding with sweep in K-town I had a creak going on, was a crack from one corner of the square to the edge of the arm.