For some reason the most popular download module does not create the correct link. I have try several different settings with no luck.

Any suggestions?

Hi,
What exactly doesn't work? Could you post some examples of SEF URLs and their associated Real non-SEF URLs from JoomSEF's URLs Manager? What version of Phoca Download component do you use? Thank you.

Here is an a sample of what is generated:

thecontractorsclub.com/index.php/http://...-club-selling-system

Here is what it should be:

thecontractorsclub.com/downloads/sales/c...-club-selling-system

Here is the url with joomsef off:

index.php?option=com_phocadownload&id=58&view=file&Itemid=208

I am using com_phocadownload_v2.1.6.zip with your paid version of Joomsef

This seems like the problem that's been around with Joomla for quite some time now. Do you have cache enabled in Joomla? If you do, try disabling it, it should help. From our reports this doesn't happen only with JoomSEF, but with the Joomla's core SEF too. Also make sure that you use the latest Joomla version.