My issues are resolved! (Famous last words)
I have absolutely no idea why (could still be my PC) but I'm wondering if values are not persisting in Sonars database, or some sort of value corruption. This is totally pie in the sky, not much logic to it, but try this...
Open Sonar, Open a projectGo to Preferences -> Sync and CachingTake note of play and record buffer size. Double them (or something)Click OKGo to Preferences -> Driver Settings.Click ASIO Panel.
Click OK to close preferences.Play your project a little.Close Sonar.Open Sonar, Open a project.Go to Preferences -> Sync and CachingPut ye olde values back into play and record buffer size.Click OK.Play project.Close Sonar.Stand on one leg. Now is there a now difference of have I sent you on a wild goose chase?
(I suspect people have different scenarios here, however it may help somebody, or maybe it's just my imaginary friend).