When you save a game or logfile, VASSAL creates a ZIP archive with a single entry named 'savedGame'. This is just for compression to save bandwidth on the email attachments. You shouldn't ever have to un-zip the file. It's possible that an email client could recognize it as a ZIP archive and try to unpack it despite the fact that it doesn't have a .zip filename extension. The unpacked file can be read by VASSAL too, so that's not the problem. It could be simply that you're forgetting to start your logfile and are just sending him a saved game instead of a logfile. Version 3.0 is adding reminders to create a logfile just for this situation.
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