Seems to happen more when temps are rising (sun coming up) then when
cooling (evening) but have heard it late at night occasionally. Would
of thought the roof would of "settled" over the last 4 or 5 years of
brutal summer heat and chilly winters (maybe just a week or two, but
still below freezing). Anything that can be done about it (beads of
contractor adhesive between roof plywood and 2x4's or something like
that?) or just something to live with? Sometimes it's pretty loud and
since it's in the front hallway it sounds like someone at the front
door :O/

No gutters so can rule that out :O)