Very interesting. Excellent debugging advice. It's giving me a 500 error, probably why the Rackspace techs told me to check my code:

HTTP/1.0 500 Internal Server Error
Date: Sat, 08 Aug 2009 00:01:10 GMT
Server: Apache/2.0.52 (Red Hat)
X-Powered-By: PHP/5.2.10
Content-Disposition: attachment; filename="Installer.bin"
Content-Length: 23223296
Connection: close
Content-Type: application/octet-stream

I'm at a loss. Nothing changed in the code and it works for ZIP files.

On Aug 7, 2009, at 4:57 PM, Adam Randall wrote:

Can you do a commandline test with curl to see what you get back?

curl -I http://url/file.php?something=here

That should allow you to see what is actually being produced by the
code, and if it's being tweaked in some manner unknown to you.

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