>I am wondering if there is a way to tell IMAIL to look at a secondary MX
>record, without hardcoding the IP address into a hosts file?

No -- that violates RFCs, and normally should not be done.

>I had this problem two weeks ago, and with the advice of some of the
>Imail guru's on here, added an entry to my IMAIL servers HOSTS file and
>was able to resolve the problem.
>
>Now, I find I am having the exact same problem again, this week, with
>sending mail to varianinc.com.

Interesting -- their primary MX record is "webshield.varianinc.com" -- 
sounds like their WebShield SMTP isn't working.

However, there doesn't seem to be a problem here -- since WebShield isn't 
answering, IMail will just go to a backup MX record.

>Once again, adding an entry to the HOSTs file, listing their secondary
>mail server IP address has solved the problem, but this fix makes me
>very uneasy for obvious reasons.
>
>Is this a bug in IMAIL or just due to poor DNS setup?

The problem you experienced before was rare (a server that was misbehaving, 
telling IMail to contact it later to send E-mail, even though it would 
never send E-mail).

This is a very different situation -- their primary mailserver isn't 
answering, so IMail will go to a backup.

Is there any indication that the mail isn't going to the backup MX records?

                                                    -Scott
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