Larry,
Thank you for volunteering!!!

I assume you have latest Sonic 3 (full, not SE) ver. 3.3.1.77 VST.
Can you follow these steps please. This is how troubles started for me...

BIAB:
1) Load a single midi track ~100-120BPM into mixer, just so it can trigger a pattern in Sonic for testing purposes, does not matter which style you choose.
2)Point it to Halion Sonic 3 VST
3)Choose patch in Halion: Ethnic->World Kit01 120
4)Go to mixer track with that midi loaded ->track actions->Save track as WAV file

When it renders, can you playback your file ok? Mine is all distorted in a very bad way.

I know this is not "original" question., but that how it all started for me and the easiest thing to check.

Again, I thank you in advance!

Misha.