I just tried simple example and it sent me 1024 bytes in one packet. Could you show us your code?

Here is the data being sent between the single quotes:

to client:'1:AAE/LxI1l9kvzveExnBSsku783Z+1mWYld/J7G3nl/OijlRXuIZXDKcHQ
+DTlkIB52p/qxiFohG76Jxhb1F64oyPpom24PO7RVvKb4jQkOoi4xNbBwSbvMUsq1ZnqNP
+95vz2ifeWzqqPmR9XRS7OfbgZSK8X3le/YP/Ca8Mj5K90aJ7oYF2HaeJFotVeCO9eLpS5
+zlH02gGMADCfS+ZXwN4420u/fwevNrBMx/cSeCVtcocS6i3wPNlJKA'
[download]

It's base64 encoded binary data. Wireshark shows the data being truncated at 128 bytes around nqNP and 95vz

And the section of code that sends it:

 my $sql="SELECT data FROM firmware_data WHERE firmware_key = '$firmwa
+re_key' AND row_number = $current_row";
$self->log(4, "select: $sql");
$sth=$dbh->prepare($sql);
$sth->execute;
$firmware_packet=$sth->fetchrow();
$sth->finish();

if (defined($firmware_packet) ){
  $IdleUserTimeout=0;     #reset the timer since we got some user data
  $self->log(4,"firmware row: $current_row");

  #send the data
  $self->log(4, "firmware to client:'$current_row:$firmware_packet'");
  print "$current_row:$firmware_packet\r\n";
  if ($current_row < $data_NumberOfRows){
    $current_row++; #get the next packet net time around
  }
  if ($firmware_packet =~ /^#bye$/){
    #we recived the BYE command, so inform the client and close the so
+cket down
    log_user_out($self, $dbh, $MAC);
    return;
  }

  select(undef, undef, undef, .5); #500ms
[download]

This is the line that sends the data, from above.
print "$current_row:$firmware_packet\r\n";

UPDATE: I'm using perl 5.8.8 on Ubuntu 8.04 LTS Server
Linux 2.6.24-23-server

Thanks for the help,
Aaron

I don't see problem here. I can suggest the following, first try my example and see if data will be sent by one chunk or will be divided onto several packets:

#!/usr/bin/perl -w
use strict;
use warnings;

package MyPackage;

use base qw(Net::Server::PreFork);

sub process_request {
    my $self = shift;
    print 'x' x 1024;
}

MyPackage->run( port => 7777 );
[download]

Second, "firmware" makes me think that there's some device on the other end. Is it able to handle packets bigger than 128 bytes? Look if there's MSS option in SYN packet.