I don't think you answered any of my questions.
For the ones where they are having problem, is it always IE?
Do you have the MIME types defined on your server? Because if you don't, it will work with IE7 but not IE6.
.application --> application/x-ms-application
.manifest --> application/x-ms-application
.deploy --> application/octet stream
If you are deploying .Net 3.5:
.msp --> application/microsoftpatch
.msu --> application/microsoftupdate
If your application uses VSTO:
.vsto --> application/x-ms-vsto
Other than that, I would go through each and every screen in the IE setup and see what is different. My guess is that there is some security setting that differs per user.
RobinS.
GoldMail.com