after bouncing to track, I get intermittent glitches on the audio track as well. I have tried several settings for the AP 192 (128, 256, 512), no difference. No, I am not overdriving the synth, it stays well within the safe zone. My output is purely analog from the breakout bundle of the sound card (2 mono TRS Connectors) to the woofer/amp (2 x RCA).

 after bouncing to track, I get intermittent glitches on the audio track as well

Your physical audio interface and your outboard connections are not involved in bouncing a softsynth to an audio track within Sonar. That operation should basically just be calculating and recording the result. If the 'glitches' are present at fixed points in the bounced audio, the problem is in Sonar, the plugin or the computer. Aside from potential problems if you are using the audio interface as your master clock source and there are problems with that clock, I can't see how the interface would be involved. You could try changing the clock source and see if that has any effect.


http://www.cakewalk.com/Documentation/default.aspx?Doc=SONAR%20X2&Lang=EN&Req=Synchronizing.03.html

If the re-imported waveform didn't show any abnormalities then you may be looking at a physical problem like a speaker cable or power cord to the speakers.  To test copy wavefile to CD/Ipod or other device and playback on a different system thats does not use the speakers your are currently monitoring with.   Another thing to try would be to unplug 1 speaker at a time to isolate if there is a problem with 1 speaker.

So what you're saying is the reason old records crackle is due to incorrect latency between the vinyl and needle? Or does the cartridge output need adjusting?

I'm so confused!

Not really.