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?

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.

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:inrecognize’
/vendor/rails/railties/lib/dispatcher.rb:40:in dispatch' /vendor/rails/railties/lib/fcgi_handler.rb:150:inprocess_request’
/vendor/rails/railties/lib/fcgi_handler.rb:54:in process!' /usr/lib/ruby/site_ruby/1.8/fcgi.rb:600:ineach_cgi’
/usr/lib/ruby/site_ruby/1.8/fcgi.rb:117:in session' /usr/lib/ruby/site_ruby/1.8/fcgi.rb:104:ineach_request’
/usr/lib/ruby/site_ruby/1.8/fcgi.rb:36:in each' /usr/lib/ruby/site_ruby/1.8/fcgi.rb:597:ineach_cgi’
/vendor/rails/railties/lib/fcgi_handler.rb:53:in process!' /vendor/rails/railties/lib/fcgi_handler.rb:23:inprocess!’
/home/sites/solid_casts/current/public/dispatch.fcgi:25

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