Hi Bitflipper...all the projects are the same, and it's not a mis-routed bus. Incidentally all my VST's that can operate as a standalone outside HS6 work fine - voice OK from both my midi keyboards and output through the behringer.
Beagle.. I hadn't tried a restore so that's going to be the next step 'cos I think I've done tried most else.
I also have X3 studio sitting here a while, so whilst my geeky son if offering his help I might just bite the bullet and go for the new one!..
Thanks to all though for the input, always appreciated
Mike