Wow, and to think its the router.
Sure enough we disabled the SPI on our netgear and file extracted with no errors, runs perfectly in poser.

TY MGD for letting us in of this!

Thank you very much, I wont try to download again though un till there is been some progress made with this issue.

1. What is your ISP?  Cox communication
2. What type of service do you have?  Cable broadband 100 Mbps.
3. What OS do you run, etc? XP Home SP 2
4. What software is used to unzip? Win rar first, then win zip tried it on my computer first and then my Boy friends, (with both zip programs) neither worked and both would unzip the file but come back with error extracting 'insert file name here' for various files. I also tried opening it with poser 7 in house  unzip/content installer.
5. Do you use any type of download manager?  the one that comes with fire fox 3
6. What Antivirus are you running? avir antivir personal down loaded two files when the issue happend the one went fine and is completely useable
7. What is file size before and after? the size for one down load attempt was 21,804kb, the second attempt was 23,300kb, and the third attempt was 20,024kb. some how I really dont think the same file should be downloading in three difrent sizes from the same site, using the same d/l manager and the same browser on the same computer.
8. Browser: Firefox 3

I've now sent two requests in to get the file reset  and I still have no reset on my file.