Have you tried calling $exp->log_file(undef) before you do $exp->log_file(\&formatoutput)? That closes the current log_file that you specified which should theoretically flush the buffer before you open the new log_file.
HTH
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That was a really good idea, but unfortunatly while in theory it should have flushed the buffer - it had no effect...sigh but thanks again for the help, when i saw you suggestion it sure seemed like it was the solution.
again i thank thee for the help
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