Thank you everything works great now!  I dropped 10 bucks in your tip jar at paypal.

The temp.zip is working correctly now.  But I found that sometimes the file count inside the temp.zip was wrong.  Some files were still being omitted from the temp.zip. This was a mystery that I wanted to solve so I tested many folders.  Customizing the temp folder location eliminated file name length as a problem. Using Windows 7 windows explorer I found files with question marks inside of a black diamond instead of a recognizable character\number.   I searched "question mark inside of a black diamond" and I found something called a Unicode Character 'REPLACEMENT CHARACTER' .

wikipedia entry is here http://en.wikipedia.org/wiki/Unicode_Specials#Replacement_character

I mostly use a Windows Xp machine so it took a while to figure it out.

The customisable temp folder setting works but strangely the resulting temp.zip is always empty!  I tried different settings on four computers all resulting in an empty temp.zip.  The only exception is if I leave the temp folder setting blank\default then it creates the temp.zip correctly.  But of course this temp.zip does not contain all the files because of the 255 limit.   :(

BTW thanks for "Files 2 Folder" I love that!