This fixed it. (I think, need to do a lot of testing)

http://www.zen-cart.com/forum/showth...wnload+problem

downloaded the file in the post
http://www.zen-cart.com/forum/attach...8&d=1155442170

replaced my download header_php.php with the one in the zip. But before hand I swapped the queries.

Im going to go through the code and see what the diferences were