Do you mind shareing the app? We might have to dig in more to nail down the exact issue.
unfortunatly the app is > 700mb and our client would probably be against us posting it here.
Could you please check that enough free space is available in the Temp folder?
i.e. C:\Documents and Settings\***\Local Settings\Temp
how do i do this? is there a limit to the size of the temp folder?
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The size of your AIR file is what is causing the unpredicatable behavior. See:
You should consider packaging your application logic and assets separately. If you are distributing the app on CD, you can write a custom installer for this, as well as put the AIR runtime on the CD so that it can be installed if needed. To do this you need to sign up for the AIR runtime redistribution program: http://www.adobe.com/products/air/runtime_distribution1.html
If you are (gulp) distributing this over the web, you could have the AIR app download the assets after install.
In any case, separating the code from the assets is a better plan if you ever plan to update the application. Otherwise, your customers must get another >700MB file, just for the update.
Any ideas on the best way to creat a custom installer for this purpose? considering the assets are 700mb
How are you distributing the app?
The app will be distruibuted on cd/dvd.
Managed to get my app size down to around 470mb and it's now installing ok
That still might be too large on some systems.
A third party installer tool might be your best bet. You can sign up for the AIR runtime redistribution program and include the runtime on the CD/DVD, too. That way it doesn't matter if AIR is already installed. The customer installer could run the required installers and copy the assets. See http://www.adobe.com/products/air/runtime_distribution1.html.
If you don't want to use a 3rd-party tool (or write your own cross-platform installer), you could have the AIR app copy the assets to a suitable directory on the hard drive the first time the user runs your application.