Creating a zip and pumping it through the headers - ERROR

Hi again, After a clever question follows a dumb one: :-( I am trying to pack a few resources from off the server, zip them together (at this stage still storing in a tmp folder and afterwards deleting it again) and make the freshly created zip file available to the user via a 'Save File' prompt. Now I have searched the archives a bit and have read the suggestions in the extended chm version of the manual TWICE, but still, I don't seem to be able to get rid of this one stupid problem: The zip gets created fine, but when I readfile() it and pump it through the headers it adds the whole html (which the server sent to the browser - not the php code) and so corrupts the zip file. I have read about suggestions to these issues, implemented these suggestion and still sit with it. I am using Apache 1.3.20, PHP 4.3.2 and mySQL on a Windows stove. The browsers I have tested this on was IE6 and Opera 7 . both acted the same way. This got me thinking that: maybe I am doing something wrong . ;-) So here is the method I am using to pack and send the stuff . [code] function PackAndSend( ) { include_once( realpath("classes/pclzip.lib.php") ); $filePath = realpath( "tmp/zips/". substr( md5( $_GET["file"] ), 0, 5 ) .".zip" ); $zip = new PclZip( $filePath ); $zip->create( realpath("files/papers/$_GET[file]"), "Resources/Docs ID [$_GET[file]]", "files/papers/" ); $fz = filesize( $filePath ); $mime_type = "application/zip"; header('Pragma: public'); // IE specific header('Cache-Control: private'); header('Cache-Control: no-cache, must-revalidate'); header('Accept-Ranges: bytes'); header('Content-Length: ' . $fz); header('Content-Type: $mime_type'); header('Content-Disposition: attachment; filename=Resources.zip'); @readfile( $filePath ); unlink( $filePath ); $GLOBALS['COPE_LOG']->devLog(); } [/code] The headers sequence I have tried with many others . all did not do anything different.] Help would be appreciated. Thomas