Ok, atleast the "mystery" of the UAC prompt is resolved. Windows 7 simply shows it if it finds "Installer" or "Setup" in the filename, I renamed the file to something else and no UAC prompt is shown. So I think that was just a red herring.

I downgraded to Python 2.6.5 and built an executable.

Comparing the contents of the two exe's using ArchiveViewer.py:

pyInstallerR6034Issue.exe (mine)
 pos, length, uncompressed, iscompressed, type, name
[(0, 567033, 567033, 0, 'z', 'outPYZ1.pyz'),
 (567033, 8308, 22705, 1, 'm', 'iu'),
 (575341, 169, 234, 1, 'm', 'struct'),
 (575510, 5988, 15712, 1, 'm', 'archive'),
 (581498, 1157, 2272, 1, 's', '_mountzlib'),
 (582655, 81, 76, 1, 's', 'useUnicode'),
 (582736, 84, 81, 1, 's', 'pyInstallerR6034Issue'),
 (582820, 38275, 96256, 1, 'b', 'win32api.pyd'),
 (621095, 6011, 11776, 1, 'b', 'select.pyd'),
 (627106, 233097, 585728, 1, 'b', 'unicodedata.pyd'),
 (860203, 36925, 71680, 1, 'b', 'bz2.pyd'),
 (897128, 602, 1857, 1, 'b', 'Microsoft.VC90.CRT.manifest'),
 (897730, 317595, 655872, 1, 'b', 'msvcr90.dll'),
 (1215325, 155722, 568832, 1, 'b', 'msvcp90.dll'),
 (1371047, 66835, 224768, 1, 'b', 'msvcm90.dll'),
 (1437882, 1054327, 2145280, 1, 'b', 'python26.dll'),
 (2492209, 42972, 110592, 1, 'b', 'pywintypes26.dll'),
 (2535181, 274, 488, 1, 'b', 'pyInstallerR6034Issue.exe.manifest')]

http://ling.uni-graz.at/~fruehwir/pyInstallerR6034Issue.exe
 pos, length, uncompressed, iscompressed, type, name
[(0, 681871, 681871, 0, 'z', 'outPYZ1.pyz'),
 (681871, 8361, 24593, 1, 'm', 'iu'),
 (690232, 169, 234, 1, 'm', 'struct'),
 (690401, 6022, 16832, 1, 'm', 'archive'),
 (696423, 1157, 2272, 1, 's', '_mountzlib'),
 (697580, 81, 76, 1, 's', 'useUnicode'),
 (697661, 108, 111, 1, 's', 'pyInstallerR6034Issue'),
 (697769, 39920, 87552, 1, 'b', '_ctypes.pyd'),
 (737689, 5444, 10240, 1, 'b', 'select.pyd'),
 (743133, 231896, 583680, 1, 'b', 'unicodedata.pyd'),
 (975029, 35130, 69632, 1, 'b', 'bz2.pyd'),
 (1010159, 391031, 805376, 1, 'b', '_ssl.pyd'),
 (1401190, 38022, 95744, 1, 'b', 'win32api.pyd'),
 (1439212, 20385, 43008, 1, 'b', '_socket.pyd'),
 (1459597, 602, 1857, 1, 'b', 'Microsoft.VC90.CRT.manifest'),
 (1460199, 317595, 655872, 1, 'b', 'msvcr90.dll'),
 (1777794, 155722, 568832, 1, 'b', 'msvcp90.dll'),
 (1933516, 66835, 224768, 1, 'b', 'msvcm90.dll'),
 (2000351, 1049758, 2262528, 1, 'b', 'python26.dll'),
 (3050109, 42514, 109568, 1, 'b', 'pywintypes26.dll'),
 (3092623, 274, 488, 1, 'b', 'pyInstallerR6034Issue.exe.manifest')]

So looking at the file sizes there are numerous differences, also some extras, _ctypes.pyd, _socket.pyd and _ssl.pyd. I'm using python.org Python, maybe the other is ActiveState?

Am 20.01.2011 19:38, schrieb Giovanni Bajo:
On Thu, 2011-01-20 at 15:47 +0100, Florian Höch wrote:
http://ling.uni-graz.at/~fruehwir/pyInstallerR6034Issue.exe

Something very strange (imho) is happening when I try and launch this
executable on my Win7 64 system (only sys I tried to run it on so far):

Can you please compare the differences between this binary and the same
binary packaged by PyInstaller on your own computer? Since the program
itself is a one-liner, and you can install the very same version of
Python, it should be possible to compare the binary file by file and see
where the difference lies.

--
Florian Höch

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