Hi Eamon,

If I understand correctly, I was having a similar problem when I was trying to put a few custom pages in my site that were totally outside of the whole Zen Cart framework.

This line in .htaccess fixed it for me:

RewriteCond %{REQUEST_URI} !^/partsrequest.php [NC]

This allowed www.mysite.com/partsrequest.php to operate normally without 404.

Hope that helps!

Sasha Shepherd
HyosungSource.com