Perhaps I've misunderstood the wording in BRainbow's post as its a little ambiguous when he says
"I always create a new sub-folder for the project withe the project's name and save to that. "
anyway all solved.
There are 3 fields in the create New Project Dialog:
Project Name: Enter <My Song>
Location: Sonar automatically appends the project name to this path eg Cakewalk Projects/My Song
Audio: Sonar automatically appends the Audio folder the full location path eg Cakewalk Projects/My Song/Audio
I don't know why but after I entered a Project Name, it didn't automatically populate the information in the Location field and Audio folder fields. I hadn't noticed. Consequently I would only get a new My Song.cwp with all the audio going into an Audio folder at the same level.
It's been bugging me for about a week now (just before Foxboro). So I went in and reset the default project location, closed Sonar, reset the location and on re-opening nothing, still the same. This time I tried a reboot after which everything works as its supposed to. Phew!