Even if the Vf of the die should be measured, those 1 ohm / 2W values are "fine" and it should not be overheating as it's probably less than 1W dissipated in that resistor. The crackling was over current leading to voltage ripple on your battery (which is forwarded to the audio amp and speaker), sign that the wiring was probably not good indeed.
This indicates a short on the tri cree wiring IMO.