I think this might be the same problem as reported in bug report 8030, but under a different web broswer.

I have a script which produces a large page (80Kb) from numerous database calls.  A little before the 64 Kb mark of the output the output is tuncated, when using AOLServer.  The exact spot depends on the broswer vieing the page, likely due to the header content different browsers send/receive.  The page is a collection of tables, all relatively small and the output is flush()ed after every table.

I created an identical file to my desired source code in one paticular example and first accessed it directly from an html filename (non-php-interpreted) and it works.  I then gave the file a php extension and had the intrepretor run over the page, it still worked.