We've been going back and forth in the Chatterbox for a bit, and I know you're pretty sure that 514 number is accurate, but I still think it isn't. I modified your code to append everything after your HTTP headers to $data, and added these two lines:

print "\$len=$len\n";
print "data length=" . length($data) . "\n";
[download]

Now in theory, these should be the same, but they aren't:

(fastolfe) eddie:~$ perl test user password test.file
$len=555
data length=580
[download]

Try adding 25 to your number and see if your problem goes away.. *shrug*.

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