=== lib/RT/Action/SendEmail.pm
==================================================================
--- lib/RT/Action/SendEmail.pm	(revision 9430)
+++ lib/RT/Action/SendEmail.pm	(local)
@@ -946,25 +946,33 @@
     $max = int($max/3)*3;
 
     chomp $value;
-    return ($value) unless $value =~ /[^\x20-\x7e]/;
 
-    $value =~ s/\s*$//;
-    Encode::_utf8_off($value);
-    my $res = Encode::from_to( $value, "utf-8", $charset );
-   
-    if ($max > 0) {
-      # copy value and split in chuncks
-      my $str=$value;
-      my @chunks = unpack("a$max" x int(length($str)/$max 
-                                  + ((length($str) % $max) ? 1:0)), $str);
-      # encode an join chuncks
-      $value = join " ", 
-                     map encode_mimeword( $_, $encoding, $charset ), @chunks ;
-      return($value); 
-    } else {
+    if ( $max <= 0 ) {
       # gives an error...
       $RT::Logger->crit("Can't encode! Charset or encoding too big.\n");
+      return ($value);
     }
+
+    return ($value) unless $value =~ /[^\x20-\x7e]/;
+
+    $value =~ s/\s*$//;
+
+    my ($tmp, @chunks) = ('', ());
+    while ( length $value ) {
+        my $char = substr($value, 0, 1, '');
+        my $octets = Encode::encode( $charset, $char );
+        if ( length($tmp) + length($octets) > $max ) {
+            push @chunks, $tmp;
+            $tmp = '';
+        }
+        $tmp .= $octets;
+    }
+    push @chunks, $tmp if length $tmp;
+
+    # encode an join chuncks
+    $value = join "\n ",
+               map encode_mimeword( $_, $encoding, $charset ), @chunks ;
+    return($value); 
 }
 
 # }}}