I was getting a similar problem where lists would stop altogether because of illegal characters in purportedly base64 encoded attachments.
I checked for mime problems, but that's not it. I'm stripping to text/plain, 8859-1. No funky stuff.
Looking in the digest.mbox files, it looks like the messages causing problems don't have a terminating \n on the message:
--
Sharks are the best from the east to the west!!
Go Sharks!!!
Check out the latest news, etc. @ <http://www.gingerose.info>plaidworks.com 162#
So it looks like the digesting code needs to be taught to either recognize this and add it if missing, or (easier) simply throw out an extra \n when appending a message to the digest.mbox file. that's harmless in the mbox format...
Off to whack the code...
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