Just a note for anybody trying to implement a php handled download script -
We spent a long time trying to figure out why our code was eating system resources on large files.. Eventually we managed to trace it to output buffering that was being started on every page via an include.. (It was attempting to buffer the entire 600 Megs or whatever size *before* sending data to the client) if you have this problem you may want to check that first and either not start buffering or close that in the usual way :)
Hope that prevents somebody spending hours trying to fix an obscure issue.
Regards :)