I know the D in Downloads needs to be capitalized, but if the rest of the name is, that could be causing a problem. If you named the folder DOWNLOADS, rename it to Downloads. With the rest of your custom content, i.e. objects, this may not be a problem, unless CAS and Bodyshop use some different kind of logic when checking folder names.
Thanks
ancienthighway, :beer: that was the problem; after I posted I checked my d/l folder and noticed the 'caps' once I re-named the folder "
Downloads" it worked perfectly. Odd though that it worked up until today. :dontknow: