First off, should you not be using "chomp" instead of "chop"? It is a lot safer if you just want to get rid of the LF/CR

Then, you could take the following code (yours):

if ( length($_) > 80 ) {
   chop;
   do {
      print substr( $_, 0, 80 ) . "\n";
      if (length($_) > 80) {
         $_ = substr( $_, 80, length($_) - 80 );
      }
      else {
         $_ = "";
      }
   } while length($_);
}
else {
   print $_;
}
[download]

and replace it with (mine):

while (length($_) > 80) {
   print substr($_, 0, 80) . "\n";
   $_ = substr($_, 80);
}
print $_ ;
[download]

Hope this works for you. I am not sure what you want to do with the email headers, perhaps explain a little more on that topic.

Ciao for now
Zig