Bob,
You said you cleaned the pot, correct?
If that didn't take care of the problem, my next guess would be a flaky solder joint. The new RoHS lead-free solder is crap, there can be cold solder joints. Especially around the input and output jacks.
Can you return the pedal? Is there a guitar store that you can try out a new one to compare?
Keep us posted.
tung
Originally Posted by birv2