Hello,
System:
mutt, talking to local courier (0.65.0) for transmission (outgoing);
an earlier version als exhibited the problem. System used to be Debian
oldstable, now Debian stable.

Symptom:
Outgoing e-mails do not reach certain recipients, instead of
delivery I recieve an e-mail with the following message:

                           UNDELIVERABLE MAIL

Your message to the following recipients cannot be delivered:

<x...@lists.alioth.debian.org>:
    lists.alioth.debian.org [217.196.43.134]:
>>> DATA
<<< 550 Broken MIME container (Long MIME Boundary)

According to the Debian bug log [1], first message, this is because
 The rule is:
 "Encapsulation boundaries may be no longer than 70 characters, not
 counting the blank line and leading hyphens."

In our installation the boundaries of e-mails after they left our
system are (most of the time[2]) 71 characters long.

If I save the e-mail in mutt instead of sending, a shorter, completely
different boundary is in the file; if I look at the boundary after I
recieved it (e.g. via an e-mail loop, or via a mailing list) I see
that it got rewritten and now has one character too much.

I tried searching for a knob to shorten the MIME boundary, but was
unsucessfully (also in the list archive).

I tried patching courier to delimit the length of the boundary, but
this did not change the behaviour, (probably I might have overlooked
the "right" place or simply failed to understand the code, which is
quite likely).

The entire bug log, including my patches, can be found in [1], but I
can provide more information here as well (but wanted to limit to the
relevant atm not to spam the list).

Any help appreciated such that I can again reach all intended
recipients.

Thanks very much for pointers, help, etc.

Greetings

             Helge

[1] http://bugs.debian.org/582765
[2] The boundary seems to include a counter or similar, so I had one message 
    going through because this "counter" was one character less and
    hence passed the test on the remote side.
-- 
      Dr. Helge Kreutzmann                     deb...@helgefjell.de
           Dipl.-Phys.                   http://www.helgefjell.de/debian.php
        64bit GNU powered                     gpg signed mail preferred
           Help keep free software "libre": http://www.ffii.de/

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