Bristol Jonesey: Haven't tried freezing everything yet. That's my last resort as I still want to tweak. Just wouldn't mind a rough mix of the project to hear elsewhere. Going 64bit means a new PC which may or may not cure the problem!
Tom: I've got Concrete Limiter on my main bus but turning it off doesn't solve the problem. I think the problem is my Virus TI plays back out of sync when recording on another track. My timing sync in X2A is audio. I'll try internal sync just in case the TI doesn't like audio sync. PDC on/off makes no difference. I've tried big buffers but that made no difference so gone back to defaults. Midi load is light as triggering mainly arps. Audio running very well with no pops and crackles.