Varnish 3 is quite old, I know. But it's still supported by Ubuntu 14 LTS. That's why I'm still using it. I will move to a recent version soon.
In regards to the issue, I don't have any return(error) in the VCL I wrote. So maybe it's coming from somewhere in the default VCL? I read about those parameters you mentioned already, and even increased them just for testing, but didn't work at that time, testing bigger files. So in any case that would be a partial solution, because it would fail at some point with larger payloads. I'm currently using the default values for those parameters, 8K, which is very close to the threshold I manually found in the logs I posted. If you see the payload size, it's nearly 8K. Only adding or removing a few bytes in the payload changes the behaviour in Varnish. But the headers size in any case is the same, so that's why I don't understand what's happening. The payload size seems to be affecting here. Cheers
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