Thanks, jatoth and drewfx1.
 
For the JV-1080, I have the following expansion cards:
 
SR-JV80-01 Pop
SR-JV80-02 Orchestral
SR-JV80-16 Orchestral II
SR-JV80-10 Bass & Drums
 
For the Kurzweil PC2R, I have this:
 

Kurzweil PC2 Orchestral ROM Expansion Board  
 

konradh
So, I have found the standard JV patch list.  I can type in (or really cut/paste/format) the patch lists for the expansion cards.  What I don't understand is 1-what the headers should be for each section and 2-how to tell Sonar "OK, this group is EXP A, this one is EXP B, etc."
 
Same situation for the PC2R.  It's like there is a lot of information for some of the detailed steps, but I'm missing the big picture.
 
 

 
 
The "groups"  are banks defined by the bank number. in the ins file. In the .Instrument Definitions section of the file as mentioned by drewfx1. Here's an example.
 

from an ins file
.Instrument Definitions

[Roland Fantom XR (Patch)]
Patch[15488]=Fantom-X GM2 Capital
Patch[15489]=Fantom-X GM2 Var #1
Patch[15490]=Fantom-X GM2 Var #2

 
For example in the top line the 15488 is the bank number in decimal. That is preset by the synth manufacturer. You may find that number in the manual as is (decimal) or you may need to calculate it. It (the number) depends on the synth and whether the CC#0 (MSB), CC#32 (LSB) or both are used for bank changing.
 
I explain the whole assignment process at around 7:12 in the video I linked to. That shows how to do it within Sonar, but all that does is create the section of the ins file quoted above with preset names. These can be edited in the file in a text editor.
 
At around 8:00 the calculation method is explained. IIRC correctly that was for one of my Casio keyboards which uses just the CC#0 for bank changing. Each patch list in the manual includes a bank change number.
 
The calculation is (CC#0 x 128) + CC#32. The casio CC#0 for the bank being added in the video is 71. This equates to the........
 
71 x 128 = 9088. 
 
If CC#32 was used as well it would be added to that. In this case it is zero (or unused) so 9088 is the bank select number that Sonar requires to change banks.
 
I hope that all makes sense.

Konrad,
I've used the insmaker to create ins files for a Roland X30, Proteus 2000, and my Kurz X2500XS.
It grabs all of my installed samples and custom programs on the Kurz as well.
Should work for your synths. I've also tweaked the resulting ins to display custom patch names.

Also, see http://www.lilchips.com/cakewalk.htm
It's a collection of .ins and .drm files mentioned in the Sonar manual. JV1080 and some expansion cards included.

OK, here is where I am lost.
 
I THINK that when you are in DEFINE, in the left panel of the instrument definitions, you have to say something like "11928 = PRESET BANK A, 11930 = PRESET BANK B," or some such.  Then in the ins file, you have a list of patch names underneath a bank like this:
 
[PRESET BANK A]
1=Piano
2=Organ
whatever and etc...
 
The problem is that when I look at existing instruments in Preferences, the bank names don't seem to match what's in the ins file.  So......
 
Please tell me if this is correct:
 
1-I calculate the Bank Numbers (e.g., Orch Expansion 1 is in slot B and acc to the manual that would be bank 1098 or whatever).
2-In the left side of DEFINE, under the instrument name, I would enter all the banks (e.g., one would be 1098=ORCH EXP B)
3-Then in my *.ins file, which has to have the proper headers, I would have a section that starts with [ORCH EXP B] and Sonar would magically find the right spot in the flat file.
 
So frustrating because I did all this years ago, but now the documentation seems to be very detailed on each specific topic but a-does not give the big picture and b-does not seem to be aimed at someone who has to create or edit an ins file.
 
 
 

Personally I have only ever assigned the patch name file to the instrument file using drag & drop. I.e. drag the patch name list across and enter the bank number when prompted, as per the video.
 
I find the whole process of creation and assignment much easier from within Sonar rather than using a text editor. I have edited existing files that way though.
 
Is there a reason you don't want to create or edit from within Sonar? It seems to over complicate the whole process trying to do it externally. 

Here is my reason: it seems easier to copy/paste a long list of patch names into a text file (ins file) than to drag them one by one into Sonar.
 
I am certainly not against using your method, but with 800-900 patch names for just one synth, copying from the manufacturer's pdf into a text file seems easier.  (I can do find and replace to format the list as needed.)
 
I am open to your method, though.  Thanks for replying!

Yes I understand that but my point (which I don't think I've made clear) is create the file in Sonar and then add the patch names later in the editor.
 
That way all the more complex formatting is already done by Sonar and you only have to copy and paste the patch names.

I agree with OP, this is confusing as hell (and I'm an engineer by day)
For my Fantom XR and Proteus 2000, I had to chase down .INS files from the internet and piece them together. Finally, I came up with a big text file and just deleted the expansion cards I didn't have. Then I imported that into Sonar. It was painful, and new versions of Sonar make you re-do it, so i get to re-learn it every year.
It seems it wants you to have a single Instrument --like "Fantom XR" and then inside that Bank Change info and the Bank names.
Then under there, the patch names inside the banks.
 
Inside of that txt file is this:
 
; ----------------------------------------------------------------------
.Instrument Definitions
[Fantom XR ]
Patch[11200]=Fantom XR PRA
Patch[11201]=Fantom XR PRB
Patch[11202]=Fantom XR PRC
Patch[11203]=Fantom XR PRD
Patch[11204]=Fantom XR PRE
Patch[11205]=Fantom XR PRF
Patch[11206]=Fantom XR PRG
Patch[11207]=Fantom XR PRH
Patch[11208]=Fantom XR PRI
Patch[11072]=Fantom-X PRESET Rhythm 001-040
Patch[15360]=Fantom-X GM2 Rhythm Sets 001-009
Patch[11904]=SRX-01 Dynamic Drum Kits 1-41
Patch[11776]=SRX-01 Dynamic Drum Kits Drums
Patch[11908]=SRX-05 Supreme Dance 1-128
Patch[11909]=SRX-05 Supreme Dance 129-256
Patch[11910]=SRX-05 Supreme Dance 257-312
Patch[11780]=SRX-05 Supreme Dance Drums
Patch[11919]=SRX-08 Platinum Trax 1-128
Patch[11920]=SRX-08 Platinum Trax 129-256
Patch[11921]=SRX-08 Platinum Trax 257-384
Patch[11922]=SRX-08 Platinum Trax 385-448
Patch[11791]=SRX-08 Platinum Trax Drums
 
.Patch Names
[Fantom XR PRA] 0=1:So true...
1=2:ConcertPiano
2=3:Warm Piano
3=4:Warm Pad Pno
4=5:Warm Str Pno
5=6:BealeSt Walk
6=7:Rapsody
7=8:JD-800 Piano
...
(((((continues this way))))
126=127:BluNoteStrat
127=128:FS Funk Gtr
[Fantom XR PRB]
0=1:GK Dubguitar
1=2:& Scratchee
 
(((((continues this way))))
 
Every single time, I have to manually type in the bank change number, incrementing by 1 each time.

soundsubs
... It was painful, and new versions of Sonar make you re-do it, so i get to re-learn it every year. ...
 

If you don't want to just overwrite the newly-released master.ins file with your old one, you can import from your old one (or from any other one you find, e.g. at lilchips). The import function lets you choose which instruments you want to import. Not to say relearning it isn't good once in a while ...