On 20 Dec 2019, at 18:08, Jack Bailey via Exim-users <[email protected]> 
wrote:
> header_maxsize was not in my exim.conf.  It is now.

Something is definitely wrong here - if that is unset in your config, it should 
be 1M by default (set in Local/Makefile at build time). From the docs:

https://www.exim.org/exim-html-current/doc/html/spec_html/ch-main_configuration.html

> header_maxsize        Use: main       Type: integer   Default: see below
> This option controls the overall maximum size of a message’s header section. 
> The default is the value of HEADER_MAXSIZE in Local/Makefile; the default for 
> that is 1M. Messages with larger header sections are rejected.

I would be very, very surprised if whatever OS your package has come from has 
overridden that with an insanely large number.

You don’t have any header rewrite rules, filter rules or something like 
procmail/formail/sieve doing anything weird, do you?

Graeme
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