I'm seeing the same issue as #321026: HTML messages are broken by line breaks with long lines on HTMLMail emails (caused by a View and its many div wrappers combined with transmorgrification of the CSS styles for each div).
I've worked around it by turning off the wrapper CSS for the view in question, but in looking for the problem I discovered #321026 and noticed how they solved it just recently with a patch: http://drupal.org/files/mimemail-321026-42.patch. I see that you've posted on that issue thread so you are likely familiar with it, but the patch there is quite recent.
Could a similar technique as that patch be used for HtmlMail / MailMIME? ie. check the length of the HTML lines and if > 998 chars, use base64 encoding instead of plain? I could try porting the patch over if I you let me know the correct module/place to do so. I can turn the CSS wrappers back on on my view and it will reproduce it easy enough for testing.
Comments
Comment #1
pillarsdotnet commentedPatches are always welcome.
Comment #2
damien_vancouver commentedOK cool, if I run into it again I will try and create one. Thanks!