I've found an old post about this problem, it seems that you can unpack 
the zip file from a console window without needing to install Stuffit or 
anything else.
> Yes, that was the problem!!  It seems that OSX double click on
> > the .*zip* was also taking the extra step and unpacking the .xpi file
> > without notification.  If anyone else has this problem, then try from
> > a console window and manually do a 'unzip hotmail-1-2-17b1.*zip*' this
> > will unpack just the .xpi file which can then be installed as descibed
> > elsewhere in this thread. 

AngelRicardo wrote:
> Download and use Stuffit Expander this is the one that decompres at
> the first level leaving the xpi intact, if use archive utility it
> expand all and damaged the xpi. make a test before to expand give a
> right click and verify what is your defaul program and in open with
> chosse Stuffi Expander
>
> On May 24, 7:52 pm, jason <[email protected]> wrote:
>   
>> Had the same problem. Just used stuffit, which did the same as the
>> archive utility but did it in two steps, leaving the xpi file in the
>> same directory.
>>
>> On May 24, 7:33 pm, Webmail Author <[email protected]> wrote:
>>
>>     
>>> The Mac unzip tool is a bit to clever, it's unziping zip container and
>>> the xpi inside.  You need to find a way of stop the unzip all behavior
>>>       
> >
>
>   

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