The problem with that idea is that this whole process is handled by the
software. The software creates the report or item, generates a .pdf,
attaches the pdf to the specified outlook express acount and sends it
to the address / addresses specified before the software ever creates
the report. This is all done in the background so you cant specify to
zip the file up as you would have to have a zip utility interfaced to
the software or written into it, which again would be a programming
item.

The major concern is that this only happens to .pdf's over 1mb in size
that are sent through certain ISP mail servers. I literally have dozens
of customers whose mail servers handle this without any issues, just
slap in the account info and tell the software the name of the outlook
account. So based on everything I have tested the issue is between
Outlook Express and the E-Mail service provider but I would hope for
something on the Outlook Express side to make it work. what is the
difference between how Outlook (2003) sends an email and how Outlook
Express (6.0) sends an email?

I'm not experienced in this particular problem, but I've found that when I
have issues like that, zipping the file and sending it as an attachment
takes care of the problem for me.
When you break apart messages, BTW, they have to be re-assembled at the
other end before they can be used. Combine and decode maybe?

Just my 2 cents

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