Thanks everyone. I maybe should have clarified that i run all clones through their own respective buses, this leaves me with a bunch of clones but they all just have a master volume bus. I also should have said the music is metal.
I do typically leave the master around -6 dB (this seems to be where the red starts on the Vu meters if I remember correctly).
I also only use Sonar for level checks, it doesn't seem smart to check the volume through anything other than the DAW (however, we have mixed down a rough track just to hear it in the car).
I was planning on using all limiter / compressor processing at the mastering stage (not quite that far along ATM) using Ozone.
Cloning and sending the clones through a bus does seem to increase the overall volume and increases the value of the Vu meters, but based on what you have all said here, it seems this is not a good method.
If nudging becomes necessary (god knows it has been with the drums), I delete all clones before I start. With the intention to reduce the chances of phase / time issues.
I typically export to 24 bit wav for all purposes. It seems that 32 bit is not recognized by some software / media players.
I will check out the links above, and begin prepping for the master stage.
Thanks again everyone!