Stuffit & zip files won't unarchive completely

Here's another issue I'm having (I've got time today, so I figure I'll get them all out there:)
I recieved a sit file from a client through email (I'm using Mail). When I tried to unstuff it, it wouldn't unarchive completely. The stuffit progress bar got about 3/4 full, then stopped & estimated time started going up to like 272875 hours.
I let it continue for a while (about an hour...it was only a 1mb file btw) but eventually had to force quit stuffit, although it never actually froze or crashed. Then I noticed that the file it created on my desktop had some, but not all, of the items inside. This file was reading a size of 3 gb!!!
So, I had the client re-stuff & re-send.
Same issue.
I tried opening stuffit expander & dropping the file on to the icon and tried file / expand in the menu.
No dice.
I tried opening w/ older version of stuffit deluxe 6.
Nope. File type not supported.
I even asked the client to try zipping the file using osx's built-in functionality, but then I got "Unable to unarchive (Error - 1 Operation not permitted)" from Archive Utility.
I just don't know if it's a problem w/ stuffit, or if something's getting weird throught the file transfer, or it's if it's an os thing. Anyone out there hear of something like this happening before?
I'm running osx 10.4.6 & stuffit expander 10.0.2.
Client is running osx 10.3.9 & stuffit 7.
Thanks:)

Can you use the command-line "unzip" tool to look at the archive's contents (maybe there are filenames that have weird characters or are otherwise troublesome on some OS X disks) and do an integrity check? If the archive is called Archive.zip in your home directory, use the command unzip -lt Archive.zip in a Terminal.app window.
Can you use that same tool to expand the archive? unzip -v Archive.zip (-v will give some information about each file as it goes, so you might be able to see at what point it has trouble).

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If I were to take 10 hours painting my images fantastic, I
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Stuffit & zip files won't unarchive completely

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