Ok, so I ran the DPC latency checker, average latency seems to be around 50-100 us. It will spike to 200-300 us when opening a new program like firefox or chrome (max 373).
I then tried running Sonar with it, no appreciable spikes, but the sound is still stuttering. I then started deleting plugins, but the crakling was still there when I got all the way down to 1 instance of Play.
Note that this project was playing fine with 4 instances of Play, and then it stopped.
I then tried lowering latency in the Scarlet mix to 4ms and 3 ms, nothing. at 2ms, I got the audio has stopped warning.
Very strange...
I load up a new project with several instances of play, but Session Drummer, Punch, BreakTweaker, Stylus RMX, Stuttter Edit, and that seems to be playing fine (for now) Latency at 5 or 8 ms.
Note that I still have DPS running in the background, and even with all this playing, I'm right around 50 us. Also note that even with the other project's audio messing up, there were no latency spikes.
I think next, I'm going to try and recreate that project from scratch, something funny has to be going on.