Hi - thanks for the idea cswami - Although I don't think this is the issue. It happens whether I am running everything dry or with effects. I'm also running the 32bit version of Sonar now, so Bit Bridge isn't even coming into the equation..
So I have some interesting developments on this front. So my buffer level "fix" did not really pan out after some extensive testing. So I spent a lot of yesterday diving into the system. I busted out LatencyMon (thanks KevinD) to take a look at my system drivers. Previously I'd only used DPC Latency Checker, which doesn't provide much detail. That sent me down the road of playing with my graphics card drivers (I have dual Nvidia cards - 500GTX and a 620 that are driving 3 monitors). LatencyMon found huge issues with the drivers. After some research, I found I wasn't the only one with that problem (like you Kevin). I went through a couple revisions and ended up loading the default Win7 VGA drivers to eliminate the driver. I was still having pops/dropouts.
So after a preemptive trip to MicroCenter this morning with a new ATI video card, I started testing again. Most of my high DPC hangs were with usbport.sys, wdf01000.sys, and the built-in atapi driver. So I removed all USB devices (short of a keyboard,mouse) and unplugged my internal BluRay drive. Still having problems (and LatencyMon telling me that I am). So I went into the BIOS, updated to latest version, turned off ALL power management and CPU scaling functionality, booted back into windows and made sure that all of my Windows Power items were set to maximum, disabled the power down checkbox in device manager for each of my USB root hubs. STILL having dropouts in Sonar. For giggles, I fired up reaper and played my multitrack test project (15 audio tracks, just like Sonar of me playing a simple groove with no effects). LatencyMon kept barking to me about problems with drivers/power management, etc, but it sounded absolutely fine.
So I was back to playing with Sonar. I happened to run across this thread:
http://forum.cakewalk.com/tm.aspx?m=1427501 I did a bit more reading about MMCSS and on a whim, disabled it. I restarted my test project (after a reboot) and ran LatencyMon. It still barked at me about my drivers, BUT playback was flawless. So I cued up a new project and recorded 48 bars of drums to a click track. Playback again was flawless, even though LatencyMon was complaining about my drivers.
Now this DAW system is only used for this purpose. I don't surf the internet, check Facebook, or watch movies (those are what my linux boxes are for). It's sole purpose in life is to run Sonar. If I didn't run Sonar, I would still be running Reaper in Linux, as I do on my laptop. Regardless of what LatencyMon tells me, as long as my audio doesn't pop/skip, I'm OK with things. From what I read about MMCSS, it's mainly for interacting with other audio systems to ensure thread priority. If I leave this off, do I run the risk of having problems when using a few soft synths within the confines of Sonar (Omnisphere, OPX, etc...)?
Swamptooth - I haven't messed with my aud.ini file, but if that is something that you guys think is worth exploring, I will. However, if disabling mmcss isn't super harmful and it fixes my issue (only time will tell), I'm happy with that.