Hi dm,
Umm, I really don't have a clue. Something like this happened to me ages ago, not just with chat.php but also with vB's showthread.php. And the cause was having gzip turned on in both php.ini and vB. It never showed up until after I upgraded Apache.
This doesn't apply here, since you say gzip is turned off in vB.
Ok, if it worked before, then what has changed since then?
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