My suggestion would be: get rid of the auto-patcher. Every patch it corrupts people's files, requiring them to reload AO (or, worse and more often, do a hard reload). You guys have been trying to fix it for over a year and it still causes problem and problem. You just throw more and more money (in the form of coder time) at the problem.
Downloading and patching manually works well and never corrupts. So get rid of the autopatcher option, have the system download the patch into a file and then let the user click on that file to patch. It will mean coding and CS time that you can spend on other, in-game problems.
Scorus