Added spoilers so I don't break front page.

I'm working on a backup script for my department's triage list. Unfortunately, in order to pull the information I'm forced to use WWW::Mechanize::Firefox to go through the pages and pull down the information into .html files. Then I take all of the .html pages and put them into a .zip using Archive::Zip. Once this is done I'm using Mail::Outlook to send the .zip out to my group.

All seemed to be working fine for months until I suddenly received write errors when attempting to write to the .zip file. I started working on the code and uncovered a problem where the actual files aren't being put into the .zip, they are going in empty.

Here is the code I'm using with the email portion ripped out:

When I run the above code, one of three things will happen:

1) All of the HTML files are written correctly, the Zip file is created containing all of the files, but all of the files inside the zip are 0 size containing no data.

2) All of the HTML files are written correctly, the Zip file is created containing all of the files with their correct data.

3) I receive the following error:

From what I can determine, situation 1 occurs when I delete all of the old HTML and Zip files then try from scratch. Situations 2 and 3 seemingly occur at random whenever previously created HTML and Zip files are present.

Oddly, when I create a standalone script to go through all of the files using just Archive::Zip I don't seem to have this problem.

use strict;
use warnings;

use Archive::Zip qw( :ERROR_CODES :CONSTANTS);

my @files = <*>;

my $arch = Archive::Zip->new();
my $file = 'test.zip';

$arch->addFile($_) for (@files);

my $status = $arch->overwriteAs($file);
[download]

I tried duplicating this in the original script without success.

I have a feeling that there is something simple that I'm overlooking, but I've gone through the code and through the Archive::Zip CPAN page quite a few times now without success. My other idea is that the html files aren't being written completely, but the grep seems to indicate otherwise.

Any help is appreciated.