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Here are newsgroups comments on this files issue: http://groups.google.com/groups?hl=en&lr=&...404ax.com#link5 Emax asked me to change filenames, and zip the file. I carried out test with others doing this with no difference to the 10-15% failure rate. Its likely the problem was caused by their own explanation which they finally surfaced with: We took a deeper look into some performance issue on the server and found a possibility that may be causing your downloads to cut off. In apache we have a timeout connect set to 10 seconds. What this means if a user hasn't made any type of communication to a server for more than 10 seconds the user will be discounted. This seem to be the issue with your files as you say lower the connection speed or on a dial up connection the file doesn't finish. The issue is we can not raise this limit above 10 as it will effect the server performance. You can however link to the file via FTP since FTP has no connection time out. Have since moved hosts and have no file download problems whatsoever. Cheers, Alistair+