So after a couple of long days trying things, I think I may have found the problem.
I kind of bumped into it by accident. I started by running some latency tools in Windows 10, which I didn't realize at the time, don't work so well as they were designed for Windows 7. I was noticing medium/high usage on the Nvidia display driver that were a lot worse than they really were due to incompatibilities with the tools. That lead me to try older driver versions, and even swap out the 580 for a 970 borrowed from another system. I was still seeing the problem so I decided just to go back to Windows 7 and get a sanity check and rule out drivers etc. I was finding out that this particular board did not have official Windows 10 support from ASUS anyway.
I reinstalled Windows 7 SP1, and made sure I had all the chipset drivers from ASUS and adjusted power profiles and disabled defender and other bloatware I typically had disabled. The DPC latency tools were showing my system having really low latency but get a random high mark once in a while. It wasn't around any specific driver though. I installed one of the smaller games I knew I could reproduce with occasionally by just loading the launcher, and sure enough, I was now seeing dropouts in the mixer in Windows 7! ( There goes my thread title!) I wasn't sure what to think, this system has been stable for a long time on this same OS and setup.
Anyhow, I started doing some research, and came across some articles on HPET ( High Precision Event Timer) and it's effect or lack therof on DPC/latency. Basically you need to have it on in the bios AND the OS for the OS to use it. Windows 10 supposedly uses a different, 'better' timer and my Windows 7 clean install didn't have it enabled in the OS by default, so it was defaulted to whatever older timer it uses.
Most of the info I found online was from "gamers" trying to fix frame rate microstutters but also audio problems caused by latency issues. There were 2 camps I was seeing in my searches. Some folks were getting better DPC results disabling HPET altogether, and some folks were getting better results enabling it both in BIOS and OS. It also seems very system/motherboard specific if either even helped.
I figured I would try it. I enabled HPET in the OS by running this command I found bcdedit /set useplatformclock true ( it's also enabled in the BIOS at this point). I shut down so the settings could take effect. About the same. I then disabled HPET in the OS using bcdedit /deletevalue useplatformclock and rebooted into the BIOS and disabled it there at a hardware level and restarted.....
I don't want to jinx it, but I can't get the Lynx Mixer for the AES16 to dropout after several hours of trying. I put up a few browser windows with some streaming video at the same time as launching multiple game launchers...rock solid. I'm kind of confused by the whole situation really. All the other BIOS settings are still set from years ago, so it doesn't look like something that would have been reset back to on, if it had been off. Maybe it's a combination of newer updates somewhere in the OS or maybe newer AES16 drivers don't like it, I'm not sure!? Either way, there's something about this being on at a hardware level that causes problems, even when the OS is not set to use a HPET explicitly. Maybe the board is going?
I was planning on upgrading to a 6700k/Z170 platform soon because there are fewer and fewer boards that are made with PCI slots that are 'decent' these days ( pretty much only midrange boards with just enough 'new' features), and I was hoping to buy in now and get another generation out this AES16-SRC.
After some more research though, it looks like most boards don't give you the option to disable HPET at a hardware level anymore. I guess mixing rather old and slower PCI tech along with faster tech may have finally run its course? Maybe I'll just have to bite the bullet and buy a new interface for the Aurora 8, or gamble that it's just this specific board and its timer that are the problem.
Edited by Brent - January/10/2016 at 11:24pm