So. I’m I going to get a reply here at all. This is a support page isn’t it.
You already got your answer and, of course, my guess was CORRECT. See my previous reply:
Could be this file is larger than the default 2MB threshold for a file to be possibly considered an AFCAD ?
And, according to your own report, IT IS:
The bgl file is 3.2mb.
But I know I never edited any ini file on my last install. So why would it work then and not now.
Regardless of what you think you know or you remember, as I've said, GSX BY DEFAULT, excludes all files larger than 2MB, UNLESS you edit the %APPDATA%\Virtuali\Couatl.INI file and add the airportCacheMaxBGLSizeBytes parameter to an higher value. It has been like this since GSX came out so yes, if the file was always that big, you DID edit the Couatl.INI file and forget about it.
If the file is not there, you must create it, and add this line:
airportCacheMaxBGLSizeBytes = 4000000
This will allow .BGL files up to 4MB to be used