So.... I froze the BFD3 synth - it took a long time! (25 mins), which led me to believe something was odd.
Sure enough, Sonar's audio engine crashes whenever I play back the rendered BFD3 audio, Unfreezing BFD3 (which removes the rendered audio) restored stability and everything played fine "live".
After unfreezing the synth, I noticed when playing the MIDI data through BFD3 routed to individual Sonar tracks, all BFD3 waveforms display as stereo in trackview with waveform preview enabled, despite me selecting all audio outputs to be mono in the synth rack's open synth dialog. I also checked each drum kit piece output is set as mono in BFD3, except for the overhead ambient mics, which are stereo.
As a test, I manually created a mono audio track for the snare, set the input to BFD3's snare kit piece output and the waveforms still display as stereo with preview enabled when playing the MIDI data through BFD3.
I'm not sure, but suspect whatever's causing the mono / stereo mismatch is contributing to the rendered audio being unplayable. I'm clearly doing something wrong and am getting desperate. I have to send the rendered audio in an OMF to an engineer asap.
I'll try converting the stereo clips to mono to see if that helps, but am curious if anybody can detect what I'm doing wrong in my routing, as I have many other songs to render.
Any help would be greatly appreciated.
Thanks
Russ