I’m actually still seeing this one and I’m on 0.9.2.4. Same details as Jonathan described. And the ‘download’ that starts being served up when the home page is accessed is either the gibberish file, or is just a download of the homepage html code. Removing and then re-adding the W3PC code from .htaccess fixed things a few days ago, but came back today. Remove/re-add did the trick again. But I’d definitely like to know why this is happening. Running on WP 3.2.1.