Hi - Rich936. :)
Lots of folks have multiple versions of Sonar installed, and they do live happily installed alongside of each other, so there are still lots of folks using one or more versions of Sonar. I tend to like to finish working in projects using the same release I used when a given project was first created. (certainly not a requirement, just my personal choice there).
I am wondering if you have and 32-bit plugins getting loaded into projects running in 64-bit Sonar on your computer that are failing. LOTS of folks found their systems running with far more stability once they moved to using nothing but 64-bit plugins in 64-bit Sonar.
32-bit plugins running in a 64-bit Sonar require the loading of 'bridging software' to work, and whether that is the bridging software that comes freely with Sonar, called BitBridge, OR a 3rd-party bridging program such as JBridge, things can get quit flaky and unstable using ANY kind of bridging software, so I would suggest you look at your VST search paths in the Cakewalk Plugin Manager and see if you are including any folders containing 32-bit plugins that are getting loaded into these failing projects. You would also see either BitBridge or JBridge using Task Manager, if any 32-bit plugins are indeed being used in a 64-bit Sonar environment.
For any project I absolutely would require any 32-bit plugins, I would do so either after testing any of those plugins to make sure they seemed stable, OR I would build the project using a 32-bit install of Sonar. Lots of folks install Sonar in both 64-bit and 32-bit, and that creates no conflict. I have deliberately moved to doing any new work only working with 64-bit plugins, and my system runs WAY more stable than it did when I was bridging.
You may also do a Reset and a FULL Rescan of your VST plugins, which was a requirement at some point in either X1, X2, or X3 (cannot recall when that was mentioned, but I did do that at some point in the past).
You might also consider seeing if opening a project that had been failing in Sonar's 'Safe Mode' and skipping the loading of all of the plugins results in eliminating the crashes, as that would indicate one or more plugins loaded into that project are failing for some reason when allowed to be loaded. (do NOT save the project if you skip the load of the plugins, just close it without saving if you have skipped loading of the plugs when testing project stability).
One additional thing to look at would be to go into Preferences to see if the option is checked for Sonar to use the 64-bit Double-Precision Engine, and if it IS checked, try removing that check and clicking on Apply, then seeing if THAT makes things export properly. I believe that was recommended for folks to do if they were having stability issues when exporting.
Anyways - I would suggest you give the above a shot and see if that helps. I will circle back to this thread when additional responses are posted, later this afternoon and then either tonight or tomorrow, to see how things are working at that point.
Bob Bone