A-HA! I think I know what's wrong...
In your client, before you enter your username/password, go into Options and turn off texture caching. Apparently the client builds a texture cache on your hard drive and loads from that instead of from the .S3D file. It probably works for me because I have it off (or never had it on). Try turning it off and then see what happens.
(crosses fingers)
WC
P.S. My ZP server is up for now for anyone else who wants to try out the two zones in the OpenZone zonepack.
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