I can take a look at the saved game, but I don't know how much more I can try that you have not already done.
There are no freeware programs that support compressing to the rar format, AFAIK, and due to licensing issues I don't think there can be. For compression, I usually use
7-Zip; it achieves a better compression ration for zip files than other programs, and its own 7z format can be much better (can be made self-extracting, so the file recipient would not have to have 7-Zip, and with the 4.x beta it supports multivolume archives).
freeware archive managers 
