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All that said, I'm sorry Mark but are you sure that file is encoded properly? VLC definitely gave me an error when opening it, but it still played afterwards. That says to me: "encoding issue."

Yeah, the real file is fine -- the sample.avi I provided is just a raw chop of the first 5MB of the real file, missing the index from the tail end etc.. which is why vlc complains (but plays it fine regardless).

Cheers