I've been experiencing random pops/clicks/dropouts during playback and the only thing that fixes it is to max out my buffer size to 2048 (in Sonar and Saffire). It doesn't matter how big the project is. It seems to happen on everything. All drivers (firewire, graphics, Saffire) are up to date. My system specs are in my sig.
 
Anything jump out at anyone?

Hi,turn off all wifi and power saving stuff on your MB set up.
Turn off the windows UAC,it's terrible on audio driver priority,especially for ASIO.
I have a lower spec and i use 3.5 ms on Focusrite Saffire Pro 24.
Let me know....good luck.

i forgot the W7 power managemet....change the CPU on 100%

What Driver mode are you using for the Echo card? If your using ASIO ,Try WDM and visa versa
 
CJ

Be sure to increase the midi and audio buffers as well. They need to be able to "look ahead" far enough to get everything processed. Do you run a large number of synths in the project? If so, try bouncing them to audio (or freeze the synths ) and archive to disable the synth processing. See how it plays back when everything is in the audio world.
 
Quite often this will solve the issue.
 
You said you have a focusrite interface, so you certainly want to try using the ASIO drivers first.

As for drivers, I am using ASIO. My projects are primarily audio with Superior Drummer but the glitches occur on audio only projects as well.
 
Windows UAC is turned off. I've optimized per Sweetwater's optimization guide.
 

Try running DPC latency checker, (google it) if you are see large spikes, try disabling different devices one at a time and re-test,
the "goto" one I'd try first is any network cards/devices, just disable it in device manager. 

Mistergreen
As for drivers, I am using ASIO. My projects are primarily audio with Superior Drummer but the glitches occur on audio only projects as well.
 
Windows UAC is turned off. I've optimized per Sweetwater's optimization guide.
 

So try using WDM driver mode
As i said in my other post above, you need to try both driver modes. One is not better than the other.

Agreed... sometimes a driver other than ASIO (which is generally better) will in fact work better.
 
Be sure to try converting all the synths to audio and shutoff the synths so they are not taking up the processing power.  Audio only projects do tend to run smoother.

CJaysMusic

Mistergreen
As for drivers, I am using ASIO. My projects are primarily audio with Superior Drummer but the glitches occur on audio only projects as well.
 
Windows UAC is turned off. I've optimized per Sweetwater's optimization guide.
 

So try using WDM driver mode
As i said in my other post above, you need to try both driver modes. One is not better than the other.

I have tried the WDM. That's makes things almost unplayable.