You can right click any clip in the track pane and choose "Convert to Mono", so that easily resolved.
 
If you decide to freeze the synth, you can choose whether or not it's frozen using a fast bounce or a real time bounce. 
Just right click the synth icon on the Midi track and choose "Freeze Options"

Bristol_Jonesey
You can right click any clip in the track pane and choose "Convert to Mono", so that easily resolved.
 
If you decide to freeze the synth, you can choose whether or not it's frozen using a fast bounce or a real time bounce. 
Just right click the synth icon on the Midi track and choose "Freeze Options"

Ah, cool. So Freeze may still be on the table if the Multi Select > Freeze idea works. The other potential solution would be to disengage anti machine gun mode but then that requires more attention to the note velocities of the MIDI track and perhaps still result in variations between tracks (but maybe not and I'm just paranoid).
 
Thanks again Jonesey (and brundlefly).

I'm still trying to get BFD to run it's own export. No luck yet but I'l try and get it working and report back

I'm not sure if Eco has some of the fancier export options. I read to whole manual the other day and nothing really stood out. The only thing I've been able to get it to do (and this was ages ago) was export a stereo wave from the standalone of some grooves slap together on that ridonculous internal timeline thingie. There was a brief mention of being able to export MIDI grooves but this is a MIDI track I played/wrote within Sonar. Unless I can somehow import it into BFD then export it again... but that sounds like a pain and I'm not sure exactly how it would help this situation.
 
What we got going here in this thread should be fine. It's just a limitation/quirk with Sonar that can be worked around. I checked the waves and they sound fine. Actually I almost think they sound better than the synth playback. Like they're clearer or something. More realistic. Tomorrow I'm going to export the toms one at a time as helper tracks. I ran out of output channels so I figured the toms being bounced from different passes wouldn't conflict with the OHs/Room tracks as much as doing the cymbals on different passes. Also because I made sure to get the pan and levels right for the grouped tom output I did today that will be dominant in the mix and the extra tom tracks will just be there to beef things up if I need.
 
This sure has been a lot of brain work. Confusing stuff this routing business. The full BFD would make this a lot easier with the extra outputs but there ain't no cash for that right now.
 
Edit: You know I just realized to the casual observer who hasn't been watching my escapades with this I may have made it sound like a) using BFD is ultra complex (it is kind of but not THAT bad) and/or b) I'm a total bafoon (which is debatable I guess.. lol). Really the reason this has been such an ordeal is because of what I'm trying to do. There are obviously many other simpler ways to get a drum track (which I've already done successfully many times) but I'm trying to replicate the exact type of track set up one would get recording a live kit in the studio. I may type up the entire procedure I followed and the reasons why I did specific things (torturing myself in the process). Some may find it useful or at least interesting. Really though this has been quite arduous and I know I certainly could have benefited from a step by step guide.
 
Cheers and thanks to everyone who helped me figure this out.

Bristol_Jonesey
I haven't read all 3 of your posts beep, but if it was me, I'd select "All Synth Outputs: Mono" when inserting BFD
 
Then you have 2 jobs to do:
 

1. Delete all the duplicates
2. Set your Overheads/Room to stereo via Sonar's track interelave

I would probably do a manual setup, then save it as a track template, so I'd:
 
1. Select Insert Synth and use the "First Output" option
2. In BFD Eco's mixer, route the Kick to the Kick output, Snare to the Snare output, etc., so all channels are on a unique output*
3. In Sonar, with the In/Out option module turned on in the console, I'm going to reassign track 1 the "Kick (left)" output option (name your track in Sonar as you go along)
 
Why "Kick (Left)"? Because ECO actually gives you two mono outputs for each drum and a stereo output for that drum. The two mono outputs are just duplicates of the same track, and there's no need for stereo on the direct channels because they're mono.
 
4. Then I'm going to insert another track and select the "Snare (left)" option
5. Repeat this for the direct channels on all kit pieces using the "(left)" output option
6. Once all your mono outputs are set, insert a new track and select the "OH (stereo)" option
7. Then insert and add "Room (stereo)" as the output option, assign any aux busses the same way
 
 
While it's a bit slower, I find the manual approach ends up being cleaner as it gets me only the channels I use, and in the order I want them in. I'm also not ending up with a bunch of unused tracks I need to go in and delete after working backwards to figure out what's assigned to what.
 
Assigning outputs to multi-out VSTi's is another area where I really feel like Sonar can improve. In another host I use, you insert an instrument, it creates one track, in the plugin menu there's a "Channel" button, you click on that and it opens up a list of all available outputs. You check the box next to each output you want, and they're created for you on demand. It's a lot slicker than Sonar's implementation IMO.
 
*Note for BFD3 users: you can right click any channel in the mixer and use the Auto-Assign Outputs option to do this for you. It's a huge time saver.