It looks like prior bug reports didn't root out the cause of this issue. When not using imagecache, rotor calls theme('image', ...) to generate the img HTML. theme_image expects the path of the image file to be relative to the base_path of drupal. When using private downloads, the images should always reside outside of base_path.

This patch checks the download method and passes the full private download URL to theme_image if necessary. Setting the $getsize parameter causes theme_image to skip some checks on the $path.

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tedfordgif’s picture

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Better yet, get the image dimensions and pass them along to theme_image...