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ghia, the problem is with the tar file itself that's generated.
The default.tar.gz that's downloaded unpacks okay to default.tar, which generates an error when trying to unpack.
I've spent some time checking code (e.g., /class/class.tar.php) and PHP settings. I've got two xoops sites running on the same ISP's production server. The first uses xoops 2.3.3 and the default.tar.gz file unpacks okay, all the way to the default folder containing the templates folder and tplset.xml file.
The second site uses xoops 2.4.5 beta and the default.tar file extracted from the downloaded tar.gz file is bad. (On my test Ubuntu system noted in a prior post, running xoops 2.4.5, the same thing happens, namely, a bad tar file.)
I've opened the two default.tar files in TextWrangler to compare them as to format, but see no obvious problem. Binary information, of course, is not viewable.
So, this problem remains unresolved.