Rails - Aug 2006 - Weird routing error in 1.1.6 slash frozen on edge

So i have this route set up:

map.connect ''xml/download/:user/audio/:category/:file'',
:controller =>
''xml'', :action => ''download''

I am sending the user through an xml controller as it is coming from an 
RSS feed, the download action looks like this:

def download
    episode = Episode.find(params[:episode])
    episode.downloads << Download.new(:ipaddress => @request.remote_ip)
    redirect_to 
"http://www.solidcasts.com/episode/#{episode.solidcastsuser.id}/audio/#{episode.id}/#{File.basename(episode.audio)}",
:layout => false
end

we are getting ready to move to a new hardware environment supposed to 
happen today however we can''t as I have found 1.1.6 has really screwed 
up routes on me for some reason. i have had to do other freakish hard 
coded hacks to get things that were working on 1.1.4 (unpatched) as well 
as my local machine but this one seems to not be working at all (I also 
froze edge on this server)

why is this?

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On a side note if I link directly to the file that I am supposed to 
redirect to everything works as it should? Am I the only person that has 
had this whole upgrade thing screw with my routes (other than engines 
users) This whole thing has messed up require statements for me as well 
as routes now.


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here is the error I am getting in my log:

ActionController::RoutingError (no route found to match 
"/xml/download/1/audio/1/file.mp3" with {:method=>:get}): 
/vendor/rails/actionpack/lib/action_controller/routing.rb:1043:in 
`recognize_path''
    /vendor/rails/actionpack/lib/action_controller/routing.rb:1033:in 
`recognize''
    /vendor/rails/railties/lib/dispatcher.rb:40:in `dispatch''
    /vendor/rails/railties/lib/fcgi_handler.rb:150:in `process_request''
    /vendor/rails/railties/lib/fcgi_handler.rb:54:in `process!''
    /usr/lib/ruby/site_ruby/1.8/fcgi.rb:600:in `each_cgi''
    /usr/lib/ruby/site_ruby/1.8/fcgi.rb:117:in `session''
    /usr/lib/ruby/site_ruby/1.8/fcgi.rb:104:in `each_request''
    /usr/lib/ruby/site_ruby/1.8/fcgi.rb:36:in `each''
    /usr/lib/ruby/site_ruby/1.8/fcgi.rb:597:in `each_cgi''
    /vendor/rails/railties/lib/fcgi_handler.rb:53:in `process!''
    /vendor/rails/railties/lib/fcgi_handler.rb:23:in `process!''
    /home/sites/solid_casts/current/public/dispatch.fcgi:25


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