I keep getting the message out of disk space when I have over 100 gigs of space available.

Just a guess, but what file system do you have? maybe temporary file has more than 4gb size, while you have FAT32...

I should have updated this post I realized the following day that the drive letter had changed for my external backup drive when I installed a new dvd drive so it was trying to download to a none existent drive, doh.