I've been having a heckuva time with ThemeRoller the past few days. It doesn't matter what browser I use, I get the same issues.
I customize a theme without any issues then go to download it. My project requires a CSS scope, so I get that then click on download. I get offered the zip archive just fine, but when I open it up, there are a few issues.
For starters, there are no minified versions of the individual JS files. I don't use all the components so obviously don't want to put items in my code I don't need. The minified versions were definitely there a few weeks ago, so I'm not sure what changed.
Second, when I go to the themes directory, it's showing me the directory with my custom theme and all the CSS files, but ui.theme.css is blank and there is no images directory. I've tried in IE7, Chrome, and Firefox 3.6. I'm on WinXP64 and the customization link I used is below. Let me know if you need anything else from me. Thanks!
http://jqueryui.com/download/?themeParams=%3FffDefault%3DVerdana%252C+Arial%252C+sans-serif%26fwDefault%3Dnormal%26fsDefault%3D1.1em%26cornerRadius%3D6px%26bgColorHeader%3D444444%26bgTextureHeader%3D03_highlight_soft.png%26bgImgOpacityHeader%3D44%26borderColorHeader%3D333333%26fcHeader%3Dffffff%26iconColorHeader%3Dffffff%26bgColorContent%3D000000%26bgTextureContent%3D01_flat.png%26bgImgOpacityContent%3D25%26borderColorContent%3D555555%26fcContent%3Dffffff%26iconColorContent%3Dcccccc%26bgColorDefault%3D222222%26bgTextureDefault%3D03_highlight_soft.png%26bgImgOpacityDefault%3D35%26borderColorDefault%3D444444%26fcDefault%3Deeeeee%26iconColorDefault%3Dcccccc%26bgColorHover%3Dfccd40%26bgTextureHover%3D03_highlight_soft.png%26bgImgOpacityHover%3D33%26borderColorHover%3Df3b907%26fcHover%3D222222%26iconColorHover%3D222222%26bgColorActive%3D1b6cae%26bgTextureActive%3D03_highlight_soft.png%26bgImgOpacityActive%3D50%26borderColorActive%3D1b6cae%26fcActive%3Dffffff%26iconColorActive%3D222222%26bgColorHighlight%3Deeeeee%26bgTextureHighlight%3D03_highlight_soft.png%26bgImgOpacityHighlight%3D80%26borderColorHighlight%3Dcccccc%26fcHighlight%3D2e7db2%26iconColorHighlight%3D4b8e0b%26bgColorError%3Dffc73d%26bgTextureError%3D02_glass.png%26bgImgOpacityError%3D40%26borderColorError%3Dffb73d%26fcError%3D111111%26iconColorError%3Da83300%26bgColorOverlay%3D5c5c5c%26bgTextureOverlay%3D01_flat.png%26bgImgOpacityOverlay%3D50%26opacityOverlay%3D80%26bgColorShadow%3Dcccccc%26bgTextureShadow%3D01_flat.png%26bgImgOpacityShadow%3D30%26opacityShadow%3D60%26thicknessShadow%3D7px%26offsetTopShadow%3D-7px%26offsetLeftShadow%3D-7px%26cornerRadiusShadow%3D8px