I think I’ve solved the problem. I’d decided to remove my Matrox card to see if I had the playback problem without it.
In the process of tearing the computer apart, i discovered that the Kona card was loose. The aluminum bar that holds the pci cards in with the 2 knurled knobs wasn’t tight enough and both the kona and matrox card were flopping around.
After re-seating the cards, I took a pliers to the knurled knobs and made sure there was no pci wiggling going on in there. I put it all back together and everything seems to be all better.
Thanks for all the suggestions and the confirmation that it should work.
-dan