I just opened a different project, and that saves fine, no errors or freezing.
Using the same old synths and plugins I usually use, so that lessens the chance of it being them...
I think some of the audio files I've used are aiff, but audio folder shows them as wav (so obvs Sonar resaved/converted). Can't think of what it is other than Sonar just not liking the project, which is ironic as it's one of my better ones.