Hi Evan,

we are getting further in little steps, but first let me answer to your 
points...

honestly for most things you mention i have only less idea. But let me try:

1. I do not build a channel if you mean that, i write to the 
HttpServletResponse.getOutputStream, without dealing channel or not (?)
2. I did not use, i wrote directly to the outputstream, mentioned above. 
But of course i tried now wrapping in a bufferedoutputstream -> same result 
:-(.
3. I don't know. In deed i had tried the chunked transfer encoding, because 
i read about it by a google search. I am rather sure, i did it correctly, 
but
    here the client (also browser on desktop machine) even didn't recognize 
the chunked data format and wrote the complete chunked stream as is to the 
file:
    he also wrote the line seperators and the chunk size informations (what 
did i wrong here?). I don't think that this would have solved the 
connection reset anyway...
   Apart from that i did not set any chunk or buffer sizes.
4. I tried downloading from the internet (underways via mobil net) and 
through wifi at home.
5. ???
6. I updated my gwt project to 2.6.0, this did not solve anything too. And 
in the library the HttpServletResponse i use is included.
7. I do not use any further library. I just use the rather plain servlet 
api included with gwt 2.6.0.

But... let me come to the point!

My application runs within a tomcat where the server is normal http on port 
8080. For public purposes i have an apache webserver in front which uses its
own ssl certificate and can only be accessed via https ! It forwards to the 
local tomcat on http/8080. As said, this works fine on desktops and except 
downloading also on mobile phones.
So, now guess. Yesterday at home it tried download via direct access to the 
tomcat (none https) and it worked!

So, nice to know, but what could be the real problem and how to solve it? I 
do not want to download via none secure connection.

Obviously this is a problem of the android download manager which deals the 
download. In fact it seems that download via apache it does not recognize 
the header information and therefore the download fails.
My ssl certificate is not registered of course it is self signed. Might 
this be the problem? But what could i do. Is there a way to import my 
certificate in android?

But it's hard to understand. Why behaves the download manager this way, 
although the connection in browser is accepted by the user (if this is the 
problem).

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