> There's a useful function called headers_sent() which checks to see if
> the headers have already been sent to the browser. This might be a good
> place to throw into your code at various points to check and see if
> something is being written which you don't expect.

true, check that as well, moreover, you talked about utf-8, well, if the BOM is 
automatically added, it can cause lots of problems ... still, only if you sent 
whatever to the output before the download.
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