Hi everyone and thanks all for the input. First off:
Kperry - I can't hear any of my pre-recorded audio tracks.
Zargg71 - preference to share driver with other programs is unchecked
Doktor Avalanche - Sonar X3 Studio, still cjecking what aud.ini does
dcumpian - have reset the interface many times now without success
conradh - Only have one VST at a time - none of them output audio
einstein36 - I've just swapped out the Sapphire for a Behringer FCA1616 with exactly the same results, audio out everywhere except Sonar VSTs.
brundlefly and robert.e.bone - I hadn't set the windows audio to the internal sound card, but doing so doesn't make any difference - still no VST audio.
The key bit of progress seems to be that changing the interface to the Behringer (using first USB and then a Firewire connection) made no difference at all. So I conclude it has to be something to do with Sonar??
Running out of options now apart from a complete re-install -

- God I hope not....