Bigger is weird. Very weird. What client are you using when you see this problem? Is it trying to do something fancy like use multiple connections to download the file (which means it's more likely a client issue). Did it try to resume the transfer the first time because of a broken connection? If so, how far does did it rollback if any? Binary mode used? ioFTPD sort of ignore binary/ascii since there isn't any translation going on but a client could confuse that on a reconnect or something and misjudge where to pickup the transfer.
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