And everything was going so well until this error cropped up...

So what is causing this?
It would seem that later versions of php (5.0.x and later in particular) have had changes done which breaks backwards compactibilities. In addition 64bit CPU systems also display this behaviour.
Basically, the key generated by PHP for the login is invalid. Auno currently have no plans on fixing AOChat.php, but have provided a workaround using a C based PHP Extention.

Unfortunately, no one has yet compiled this extention for Windows, so unless you run *nix your still sol.

Start by grabbing the aokex extention from http://auno.org/dev/aochat/php-aokex-0.1.tar.gz or from the bottom of this post for a local mirror.
Please note that you will need the phpize program which is by default not installed on most Linux distros. The package that provides this for RPM based distros is php-devel.
Fedora and CentOS uses can simply issue as root:
yum install php-devel

Follow the instructions included in the archive for compiling aokex. Once compiled, you can normally do:
make install
This will install aokex to the system wide extention location.

The important step is to add the following line to the top of your AOChat.php:
dl("aokex.so");

Save and fire up your bot. Provided the aokex extention resides where php can find it, that should do the trick and your bot should now work

ok.. edited my post.. got a bit further now..
phpize goes good, so does configure.. then im at the make part

/root/php-aokex/aokex-gmp.c:37:17: error: gmp.h: No such file or directory
/root/php-aokex/aokex-gmp.c:44: error: syntax error before 'gmp_randstate_t'
/root/php-aokex/aokex-gmp.c:44: warning: no semicolon at end of struct or union
/root/php-aokex/aokex-gmp.c:45: warning: data definition has no type or storage class
/root/php-aokex/aokex-gmp.c:46: error: syntax error before 'dh_g'
/root/php-aokex/aokex-gmp.c:46: warning: data definition has no type or storage class
/root/php-aokex/aokex-gmp.c:47: error: syntax error before '}' token
/root/php-aokex/aokex-gmp.c: In function 'aokex_math_init':

and it goes on and on with errors.. :x

I've done this with no errors during compiling but when i load the bot it still gives the:
    AOChat: not expecting login.

php.ini
memory_limit = 20M
extension_dir = ./php_extension/

extension = sockets.so
extension = bz2.so
extension = gmp.so
anny modules I am forgetting?
also added the
  dl("aokex.so");
to the begining of the AOChat.php file and changed the $key =
/* Login functions */
    function authenticate($username, $password)
    {
      if($this->state != "auth")
        die("AOChat: not expecting authentication.\n");
     
      $key = aokex_login_key($this->serverseed, $username, $password);
      /*
      $key = $this->generate_login_key($this->serverseed, $username, $password);
      */
      $pak = new AOChatPacket("out", AOCP_LOGIN_REQUEST, array(0, $username, $key));
      $this->send_packet($pak);
      $packet = $this->get_packet();
      if($packet->type != AOCP_LOGIN_CHARLIST)
      {
        return false;
      }

Running Ubuntu 5.10 with PHP 4.4.2

Tried that, and didn't work for me :/

Any word if anyone has compiled the extensions for windows yet?

Thanks

Thanks Mawerick, now up and running on windows with php5 and the latest aochat.php from auno.org

Sorry, no. Don't have either of those installed on my windows box.

I believe the MySQL extention (since PHP4.4 and greater) for Win32 is compiled in the PHP.exe CLI.

That is I don't have any mysql.dll's defined in my php.ini and it connects. *shrug*