I have a script that uses x-accel-redirect on a nginx server to send large files (150mb+). The script serves downloads fine as long as their is a space in the name of the directory but not when the directory is a single word. Anyone know why it would be doing so when the file exists and the path is correct?

Layout: /Dir/file.exe /Dir2/file.exe /Another Dir/file.exe

If it's /Another Dir/file.exe it serves the file perfectly, however if its /Dir/file.exe it serves the html of the download page. Anyone seen this before?

nginx config:
server {
access_log logs/access_log;
access_log on;
limit_conn gulag 3;
error_log /var/log/nginx/vhost-error_log crit;
listen 80 default;
server_name www.my.com my.com;
root /home/mysite/public_html;
#root /usr/share/nginx/html;
autoindex off;
index index.php index.html index.htm;



#rewrite ^.*/([-\w\.]+)/([-\w\.]+)\.zip$ /download.php?model=$1&file=$2.zip last;
#rewrite ^.*/([-\w\.]+)/([-\w\.]+)\.exe$ /download.php?model=$1&file=$2.exe last;
#rewrite ^.*/([-\w\.]+)/([-\w\.]+)\.nbh$ /download.php?model=$1&file=$2.nbh last;
#rewrite ^.*/([-\w\.]+)/([-\w\.]+)\.rar$ /download.php?model=$1&file=$2.rar last;

error_page 503 /503.html;
location = /503.html {
root /home/mysite/public_html/errors;
}


error_page 504 /504.html;
location = /504.html {
root /home/mysite/public_html/errors;
}


# pass the PHP scripts to FastCGI server
location ~ \.php$ {
fastcgi_pass 127.0.0.1:8888;
#fastcgi_pass unix:/var/run/nginx-fcgi.sock;
fastcgi_index index.php;
fastcgi_param SCRIPT_FILENAME /home/mysite/public_html$fastcgi_script_name;
include /etc/nginx/fastcgi_params;

fastcgi_intercept_errors off;
}


}

php code:
<?php
/*File Download Script*/
$fileserver_path = "./shipped/"; // change this to the directory your files reside
$fileurlpath = "http://my.com/shipped/";
$req_file = basename($_GET['file']);
$model = $_GET['model'];
$thisfile = basename(__FILE__);
$msg="";
$error=FALSE;

$path = $model."/".$req_file;


if (empty($req_file)) {
$error=TRUE;
$msg .= "Usage: $thisfile?model=&lt;model name&gt;&amp;file=&lt;file_to_download&gt;<br />";
}

if (! isset($_GET["model"])) {
$error=TRUE;
$msg .= "No Model information present. Unable to continue.<br />";
} else {
$fileserver_path .= $model."/";
$fileurlpath .= $model."/";
/* check if file exists */
if (!file_exists($fileserver_path.$req_file)) {
$error=TRUE;
$msg .= "$req_file doesn't exist.";
}
}

/* no web spamming */
if (!preg_match("/^[a-zA-Z0-9._-]+$/", $req_file, $matches)) {
$error=TRUE;
$msg .= "Spamming! I can't do that. Sorry.";
}

if(! ($error)) {
//Hotlink Code
if(eregi($_SERVER["HTTP_HOST"], str_replace("www.", "", strtolower($_SERVER["HTTP_REFERER"]))))
{
if (! isset($_GET['send_file'])) {

Header("Refresh: 5; url=http://my.com/$thisfile?model=$model&file=$req_file&send_file=yes");

}
else {

header("Cache-Control: public");
header('Content-Description: File Transfer');
header("Content-type: application/octet-stream");
//header('Content-Type: application/force-download');
//header('Content-Length: ' . filesize($fileserver_path.$req_file));
header('Content-Disposition: attachment; filename=' . $req_file);
header("Content-Transfer-Encoding: binary");
header("X-Accel-Redirect: /shipped/" . $path);

exit;

}
//More Hotlink Code
} else {
Header("Refresh: ; url=http://my.com/$thisfile?model=$model&file=$req_file");
}
//End Hotlink
}
?>