I apparently missed some posts, sorry.
Unfortunately I don't have much to add to the suggestions.
The only additional thing that comes to mind for people having problems with cache on Windows is that I had to add some windows specific code for file opening/locking to make it work while the browser was still running.
You might try quitting the browser entirely after loading the story in cache and before trying to download it in FFF.
Clearly that isn't a good system for actual use, but it might help us diagnosis the issue.
I may also look again at some code I started once to read from WebToEpub output files instead of cache, since this doesn't seem to be going away.
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