BTW I get a weird issue whereby Sonar has the audio engine off when I start a project and I often do get Mix control starting at the wrong sample rate. Can be a PITA sometimes. I think it's the Focusrite drivers myself.

Okay, I replicated step 5, with Realtek as default:
 
5- At that point here's what I did :
I) Set the device format under Sound... to 24/96
-> I left MixControl open for this step, and adjusting this changed the Saffire
II) Set Mixcontrol to 96kHz
->Unnecessary - when adjusted in Win7, the Saffire shifted (even though not default)
III) Close MixControl
IV) Re-open MixControl
  --> the sample rate is still at 96kHz. Lets continue...
->Verified
V) Open Sonar
->I left MixControl open, SONAR shifted it back to 44.1 (was preferences in SONAR when opened)
VI) Create a project per default sample rate (96)
  --> project is created, all is good.
->SONAR shifted the Saffire to 96 (about a 1 second delay)
VI) Close Sonar
VII) Re-open MixControl
  --> sampling rate reverted back to 48kHz. SURPRISE!
->MixControl reverted back to the hardware settings when SONAR released it (44.1)
VIII) Open Sonar again
IX) Create a project per default sample rate (96)
  --> the Sample-Rate Infinite Loop of Hell is back again !!
->Saffire responded to SONAR for me (where I am scratching my head)... yes it did take about a second to "think" but shifted the Saffire without issue.
X) Close Sonar
XI) Re-open MixControl.
XII) MixControl still showing 48kHz (wrong), lets set it to 96kHz (again)
XIII) Re-open Sonar, create a project
  --> Sonar is working again.
 
I left MixControl open on the first run, and was a brief second each time SONAR reassigned the Saffire, but controlled it without issues (even reassigning sample rate to the already open project). Second run I closed/reopened MixControl, and there was another delay as this came online (about 2 seconds, with SONAR open at a sampling rate other than the hardware settings), but it still came online with the SONAR settings. I never had SONAR or MixControl "just hang."
 
The only thing that comes to mind is that the Saffire wants to revert to its hardware settings, so when things "let go" of it, it will revert to 44.1 for me (even if working in 96). If you plan to work in 96 as "default," try opening MixControl and choose "File->Save to Hardware" when set at 96. Does it still hang on you?
 
I am baffled by this now, as the only difference between us seems to be Win7 vs Win8.
 
Edit: Even Win7 sound card properties mirror SONAR driving the Saffire.

Nope, no other apps open.
I even killed some running processes (e.g. Realtek audio mixer/manager) through task manager to see if that could help, but it did not.

Try doing a quick "File->Save to Hardware" on the Saffire (when set to 96) and see if this affects the hang at all.
 
Edit: I didn't realize you were responding to Alex, I took forever typing my response!

+1.
If you are getting nowhere after this I would encourage emailing focusrite support and point them to this thread. Focusrite have responded before on Cakewalk forums, they are generally very helpful and it would be nice to hear from High Wycombe HQ again.

Btw I was hoping 3.5 would resolve these sort of issues but they only released the new version on Mac damnit :)

mettelus, may I ask what are you referring to when you say "hardware settings" ?
 
Just tried the "Save to hardware" function, alas no change.
 
On the other hand I can confirm that a change to the sample rate under Sound ctrl panel -> Playback -> Properties -> Advanced -> Default Format will be reflected immediately in the Saffire MixControl.
 
Also I can confirm that, leaving MixControl open, it drops from 96kHz back to 48kHz as soon as I close Sonar.
At next launch however, Sonar will freeze when creating or opening an existing 96kHz project, and in parallel MixControl (still open) is switching from 48 to 96 and back every second, indefinitely...
 
Default bitrate for new projects (Sonar -> Preferences -> Audio -> Driver settings) is 96kHz.
Sound ctrl panel -> Playback -> Properties -> Advanced -> Default Format is 96 kHz.
-- so where is this 48kHz that MixControl is reverting back to, where is it coming from ? Where is it set ?
 
BTW I really appreciate all the help from both of you guys!
I did email both Focusrite and Cakewalk two weeks ago; haven't heard from either for a week. Good idea sending them the link to this thread, will do!
 
I will continue testing tomorrow, it's getting late now.
 
Thanks !!

Inside MixControl, there is an option to "Save to Hardware" which I have done for 44.1 for my setup. When the Saffire is not in use by something, it seems to revert to this on its own. It seems you already tried this to no avail though.
 
For whatever reason, it seems that the handshake between SONAR and the Saffire is not the same on Win8 as it is on Win7. To me, this seems a Saffire driver issue, so definitely link this thread to them. They have always responded back to me fairly promptly, and even chimed in here.

Yesterday after my post I sent an email to Focusrite's and Cakewalk's respective tech supports.
 
I got an email this morning from Focusrite : they have been able to reproduce the issue on their end and are looking into it
 
In the interim, I'm planning to clean-install Windows 7 tonight on the rig to see if Windows 8.1 has something to do with it...

markiv2290
Yesterday after my post I sent an email to Focusrite's and Cakewalk's respective tech supports.
 
I got an email this morning from Focusrite : they have been able to reproduce the issue on their end and are looking into it

Good for you - that's how stuff gets fixed.