OP here :)

Okay, dusted off my C knowledge and made sense of what rtmpdump is doing. The reason it only goes bang right at the start is because it is doing a bit of extra sanity and set up processing on the initial packets at that stage. This is enough time to tip it over the edge and overflow the buffer.

My original tweak of changing the buffer size from 64 x 1024 bytes to 512 x 1024 bytes does not work well because it doesn't matter how many 1K buffers you have, the 1K itself is not enough. So I've now modified it to 64 x 2048 and it is now seems reliable. I've also had to mod all the percentage calculations though to take into account the doubling of the buffer length. The downloads are all fine.

Cheers
Neill.

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