Have you downloaded and run DPC Latency Checker and/or LatencyMon?
Run these with Sonar NOT running, just to get a feel for your system's base ability to handle streaming audio. You may find some spikes that could be from one or more of your background services or device drivers.
Sometimes, folks experience drops and such from things like antivirus software running while using Sonar, or they have wireless adapters enabled (they seem to wreak havoc on latency at times).
What are your reported latency values in Preferences?
Do you experience these drops and crackles when there are no effects loaded into a project? (you could start a new project and import a song file - MP3 or WMA and see if it plays back with no issues).
Additionally, you could take one of your problematic projects and try hitting 'E' on your computer keyboard to toggle off/on the Bypass All Effects function in Sonar. If after bypassing all effects your dropouts and crackles go away, that means that one or more of your plugins are causing the drops/crackles.
Here is the link to DPC Latency Checker - it's free and FABULOUS:
http://www.thesycon.de/deu/latency_check.shtml And here is the link for LatencyMon:
http://www.resplendence.com/latencymon Also, please list your settings for the following:
1. Sample Rate in Sonar
2. Record Bit-Depth in Sonar
3. Reported latency values in Sonar
4. Driver Mode in Sonar
5. Sample Rate for your audio interface
6. ASIO Buffer Size for your audio interface (sometimes expressed in number of samples)
Please review the above, run the latency detecting programs, and post back, including providing the requested information.
I am hoping we can get this sorted out for you,
Bob Bone