Thanks. I appreciate the input.
However I believe my issue is just an incomplete download. After just a quick look at D2D's faq, I found that because my download is not zipped, it's a partial download. This last time I actually watched their downloader just quit. No errors, it just stops and it won't resume the existing download when it's restarted. It starts the download all over again. What a peice of crap! Luckily you can download the file directly without that turd of a download manager by using Opera. I tried FireFox but it still launched the download manager, but Opera handles the download all by itself. So here's hoping that this works!