Couple of days ago we added a big zip file to our SharePoint deployment and out of the sudden the solution started behaving strangely. After some trial and error Robin found out that every time we cross the 360KB limit we have a problem. Wait, 360KB this rings the bell, but it was such a long time ago. What was it? You guessed it right the default limit for file size of makecab.exe is 360KB the size of 5.25 inch diskette. Talk about legacy support... To disable all kinds of limitations I added these lines to my DDF files and everything worked fine again.
You may wonder why would I need a zip file in my solution, but that's another post in the works. Stay tuned.