Well, thanks for the testy response. I suppose I should have had an intuitive understanding of your statement "it bombs out right at the client level". The stunning clarity of this statement escaped me. Now you have expressed it in terms that this dimwit can understand.
Since this ISN'T a PHP problem, something you've apparently known all the time, why did you title it "Max File Size Beyond PHP's MAX_FILE_SIZE?"
Apparently the problem is with your HTML code, yes?
Post the HTML code by which you set the maximum file size. It should be in bytes.
<INPUT TYPE="hidden" name="MAX_FILE_SIZE" value="15728640">
What happens if you remove this max_file_size html entirely?
You also write:
If the file is larger than 500K
How exact is this 500K failure. 500K works, 500K + 1 byte fails? In other words, are you bumping up against some precisely set unseen 500K limit, or is this an approximate problem that kicks in apparently variably?