Thanks for the details, but the error with the tar.gz was simply a problem with the web server applying a second dose of compression; it was using the PHP zlib output compression on the folder because someone (or more likely Plesk) deleted my .htaccess file that explicitly turned it off in the download directory.
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It’s great to hear that you got to the bottom of the problem. Sounds like it was a subtle one too. Thanks for the time spent sorting it out.
Paul