If you can leave it in the failed state the next time this happens and respond to this post, we can have a look at it.
It is now in the failed state. No code changes since last successful build.
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Hrm yes it appears part of the build chain is having issues with the size or quantity of files. Will see what we can do there.
However, you may encounter issues distributing such a large binary app package. I know you say you need those files available offline -- one solution might be to download them on first run of the app? The phonegap content-sync plugin might be of use there.
Content Sync worked great. It allowed me to have a very small and quick building binary app package. It also allowed me to have multiple zip files so that if the download failed before all zips are downloaded it would pick it up again from the failed zip and not have to start over.