My best guess is that the spot that it is choking is almost exactly 2 GB through the file, and your version of Perl is not compiled with support for large files. Therefore when it passes the 2 GB point the next seek takes it to position 0 in your file. To see whether your version supports large files, run perl -V and look for -Duselargefiles.

If that is the problem then I know of 2 solutions. One is to compile Perl with support for large files. The other is to change your open line to something like:

if(open(READ, "cat $file |")){
[download]

(I'm assuming that you are on an OS with cat installed, and that cat has support for large files.)

If you don't replace Perl, then you'll need a similar trick to write large files, because Perl will again get confused around the 2 GB mark.

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