Right if I had to paste the code it would take several pages lol. I haven't tried using a custom progress bar, but I may look into that. The main feature I used from the Progress bar was the ability to see how many "bytes" had been downloaded and I presented that to the user. I'm using a combination of urlStream/fileStream to download the file. And the source of the ProgressBar Component is linked to an instance called download which handles all the downloading of files. So I use the progress Event to monitor when a download is taking place, and at the same time calculate how many bytes have been downloaded. This is probably not the best way to do it, but currently the only way I know how with my limited actionscript 3 knowledge.
I have confirmed at least my download class/package is downloading the full file each time even though my Progress bar only works 1 time, so it could be some of the things you pointed out that is causing it.