I\'m getting some garble in my MIME headers when the subject is over 75 chars. When the line break is encoded in the header there is an extra line break that is invalid.
Apparently this is a known issue, caused by Subject lines > 75 chars.
http://codeigniter.com/forums/viewthread/154493/P15/#925385
The fix was to change the email config like this:
$config['newline'] = "\r\n"; $config['crlf'] = "\n";