Had the same problem, eventually got expander working but was furious. Started un-stuff-ing old files, along with un-rar-ing, un-ace-ing, un-exe-ing....I tar-ed anything that couldn't be compressed effectively, used 7zip on big files that could compress, gzip on a few single files, zip when I wanted easy Windows compatibility, and using dmg images on anything with a resource fork (as the others strip that). I found a few corrupted archives, one Windows virus, that neither Windows nor WinZip nor 7zip could un-zip a file that bomarchiver (OS X.3 Finder) had made, found some old files I didn't want anymore and saved much more disk space than I lost. I highly recommend getting away from the random old proprietary formats before you lose compatibility with them.
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