I'd try somewhere between 47R to 150R for the emitter resistor. A 16R load is probably a bit steep for a BC547 - I'd go for something in a TO126 package.I think it is the 1 k emitter resistor. Q3 can dump current into the capacitor and then to the headphone, but the 1k resistor needs to dump that charge on the negative half cycles as fast as the charge is added in by Q3 during the positive half cycles. This amplifier will load up a positive charge on the left of the output capacitor and then most of the current will stop flowing.