Strange error with SmartClient One Click Deployment

[Sidney Zhang]

Hi:
I got a very strange problem while using my dotNet SmartClient exe in IE.
(One Click Deployment.)
What we did are
1) a C# dotNet exe, very small, just for testing. around 492K.
2) put the exe under IIS application folder
3) make the server URL full trust on client IE.
4) Make a html page which contain the URL above.

While client the url in IE, sometime it work but sometime doesn't.
Sometimes the app just terminated without the UI shown, sometimes it will
show a error message dialog, "16 bit MS-DOS sub system, The NTVDM CPU has
encounter an ilegal instruction."

If we right click the link and save exe to harddisk, the exe might change
its size, which become 680K.
We had reprocude this problem on lots of machines, including win2k, xp, with
or without SP2. with or without norton. We've also tried to put the same exe
on different IIS server, but got similiar result.
We've also use UltraEdit to view the downloaded file header, seems it is
corrupt. ¸ since "This program cannot be run in DOS mode." in file header
become "
Lis pis pam cam ct bet be in in modemode"

My question is will microsoft IE change the downloaded exe, while oneclick
deploy?

Anyone who has encounter this before?

Thanks
Sidney