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In case anyone looks at this looking for the answer to a similar problem I wanted to say that I think I've fixed it! I'm not sure if it's a "correct" fix but it's working.
I was running the speaker cable from the sound card into two 1/4" RCA plug adapters which plugged into one of the "line in" ports on my mixing board. For the fix I took the RCA adapters off and ran the cable into the "tape in" jacks which I used for my cassette recorder to tape people while they were singing. Now I have a lot more volume with much better quality. I then went in and adjusted the volume/mixer level on the computer down. I honestly can't tell in my living room whether I have the volume I need for a show but it does get loud and I don't have the distortion I was getting with the computer settings at max.
This set up restricts my control over volume somewhat because the "tape in" line is only controlled by the main volume on the mixing board. Yes, I can control it through the computer but it gets a little complicated in a show when I'm controlling mics through the mixing board and music through the computer.
Anyway... hope this helps someone and if you have a better way to set up a computer and mixing board please let me know!
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