If it was a new hard drive, did you install Service Pack 4 after it was installed?
When you were downloading the Creator 2009 files, did you disable your firewall? That can interfere with the download process.
Any registry cleaners or anti-virus enabled when Creator 2009 was installed? That can interfere with the installation.
Creator 2009 is a year old. Roxio only supports their flagship products for free. (Flagship Products: Creator 2010, Toast 10, DVDit Pro HD 6). Yes, you will have to pay to talk to someone. But they do have live chat and web tickets all at http://selfserve.roxio.com for free. Did you try submitting a ticket and/or start a live chat?
And when you go to download your product, are you putting in the correct information? If you go to www.findmyorder.com/roxio, you enter your order number in both the order number and password files. If you have the extended download service, you will be able to download your product.
Finally, if you downloaded the product 6 times, it does sound like either an ISP or computer issue. You should only have to download it once, and the download you get from Roxio is a download manager, which you can keep on your computer incase you ever have to re-download the software.