2048 seems to work for at least the 58000 cases I’ve got here, so I’m going to stick with that. The gzip solutions makes it too slow for me (58000 times starting a process on Windows is no fun), and makes the installer larger since I need to bundle gzip.exe and cygwin1.dll with it.

So I greatly appreciate the code - I think I have also experimented with reading only pieces of the zip file into a buffer and found that the dang thing still crashes in some cases. Keep us posted on your mileage! For now I’m sticking with:

`gzip -d #{filename}`

module Zlib
    class GzipReader
        def self.read(filename)
            contents = ""
            Zlib::GzipReader.open(filename) { |gzio|
                # Max. # of bytes which can be read reliable seems to
                # be around 66500. Overflow somewhere in Zlib?
                while buf = gzio.read(65536)
                    contents << buf
                    puts contents.size
                end
            }
            contents
        end
    end
end

It seems that gzio.read() does not always work when the whole result is requested at once. Sounds like an overflow somewhere…

gem update --system