Version:            (using KDE KDE 3.5.5)
Installed from:    Ubuntu Packages

Hi, here's what happened:

Start kmail.

Created 53MB file Archive.zip (I thought it would be smaller and didn't check).

Right-click file->actions->email file.

Choose recipient, write message, send.

KMail crashes.

Restart kmail->same crash. Before it crashes it manages to bring up the window and has 1 message (the 53MB one) in the outbox the message list and preview pane aren't drawn and the status bar says 'Initialising...', then it sigabrts with the following backtrace. It does this reliably, the same each time:

(no debugging symbols found)
Using host libthread_db library "/lib/tls/i686/cmov/libthread_db.so.1".
(no debugging symbols found)
...
(no debugging symbols found)
[Thread debugging using libthread_db enabled]
[New Thread -1248819536 (LWP 5362)]
[New Thread -1277740128 (LWP 5366)]
[New Thread -1269347424 (LWP 5365)]
[New Thread -1260954720 (LWP 5364)]
[New Thread -1252562016 (LWP 5363)]
(no debugging symbols found)
...
(no debugging symbols found)
[KCrash handler]
#6  0xffffe410 in __kernel_vsyscall ()
#7  0xb787e770 in raise () from /lib/tls/i686/cmov/libc.so.6
#8  0xb787fef3 in abort () from /lib/tls/i686/cmov/libc.so.6
#9  0xb7a6f520 in __gnu_cxx::__verbose_terminate_handler ()
   from /usr/lib/libstdc++.so.6
#10 0xb7a6cf55 in std::set_unexpected () from /usr/lib/libstdc++.so.6
#11 0xb7a6cf92 in std::terminate () from /usr/lib/libstdc++.so.6
#12 0xb7a6d0ca in __cxa_throw () from /usr/lib/libstdc++.so.6
#13 0xb7a6d50e in operator new () from /usr/lib/libstdc++.so.6
#14 0xb7a6d5ed in operator new[] () from /usr/lib/libstdc++.so.6
#15 0xb6796006 in DwString::DwString () from /usr/lib/libmimelib.so.1
#16 0xb679c7e3 in DwString::_replace () from /usr/lib/libmimelib.so.1
#17 0xb67a6e77 in DwString::append () from /usr/lib/libmimelib.so.1
#18 0xb67a6f23 in DwString::append () from /usr/lib/libmimelib.so.1
#19 0xb67acbc0 in DwBody::Assemble () from /usr/lib/libmimelib.so.1
#20 0xb6793a0b in DwEntity::Assemble () from /usr/lib/libmimelib.so.1
#21 0xb7bf890f in KMMessage::asDwString () from /usr/lib/libkmailprivate.so
#22 0xb7bfb068 in KMMessage::asString () from /usr/lib/libkmailprivate.so
#23 0xb7bfd341 in KMMessage::asSendableString ()
   from /usr/lib/libkmailprivate.so
#24 0xb7d00a02 in KMSender::doSendMsgAux () from /usr/lib/libkmailprivate.so
#25 0xb7d01138 in KMSender::sendProcStarted ()
   from /usr/lib/libkmailprivate.so
#26 0xb7d045a9 in KMSender::qt_invoke () from /usr/lib/libkmailprivate.so
#27 0xb710c957 in QObject::activate_signal () from /usr/lib/libqt-mt.so.3
#28 0xb710ccb1 in QObject::activate_signal_bool () from /usr/lib/libqt-mt.so.3
#29 0xb7cfe07e in KMSendProc::started () from /usr/lib/libkmailprivate.so
#30 0xb7d03674 in KMSender::doSendMsg () from /usr/lib/libkmailprivate.so
#31 0xb7d04712 in KMSender::doSendQueued () from /usr/lib/libkmailprivate.so
#32 0xb7e16a9d in KMMainWidget::slotSendQueued ()
   from /usr/lib/libkmailprivate.so
#33 0xb7e1cad1 in KMMainWidget::slotMailChecked ()
   from /usr/lib/libkmailprivate.so
#34 0xb7e2ce5b in KMMainWidget::qt_invoke () from /usr/lib/libkmailprivate.so
#35 0xb710ca84 in QObject::activate_signal () from /usr/lib/libqt-mt.so.3
#36 0xb7cee976 in KMail::AccountManager::checkedMail ()
   from /usr/lib/libkmailprivate.so
#37 0xb7cefb55 in KMail::AccountManager::processNextCheck ()
   from /usr/lib/libkmailprivate.so
#38 0xb7cf0120 in KMail::AccountManager::singleCheckMail ()
   from /usr/lib/libkmailprivate.so
#39 0xb7d43bfd in KMail::ImapAccountBase::slotCheckQueuedFolders ()
   from /usr/lib/libkmailprivate.so
#40 0xb7d43b32 in KMail::ImapAccountBase::processNewMailSingleFolder ()
   from /usr/lib/libkmailprivate.so
#41 0xb7d6dce7 in KMFolderImap::getAndCheckFolder ()
   from /usr/lib/libkmailprivate.so
#42 0xb7e20cd5 in KMMainWidget::folderSelected ()
   from /usr/lib/libkmailprivate.so
#43 0xb7e2cc37 in KMMainWidget::qt_invoke () from /usr/lib/libkmailprivate.so
#44 0xb710ca84 in QObject::activate_signal () from /usr/lib/libqt-mt.so.3
#45 0xb7c66431 in KMFolderTree::folderSelected ()
   from /usr/lib/libkmailprivate.so
#46 0xb7c67942 in KMFolderTree::doFolderSelected ()
   from /usr/lib/libkmailprivate.so
#47 0xb7c679e5 in KMFolderTree::showFolder () from /usr/lib/libkmailprivate.so
#48 0xb7e2000b in KMMainWidget::slotShowStartupFolder ()
   from /usr/lib/libkmailprivate.so
#49 0xb7e2d605 in KMMainWidget::qt_invoke () from /usr/lib/libkmailprivate.so
#50 0xb710c957 in QObject::activate_signal () from /usr/lib/libqt-mt.so.3
#51 0xb7498f44 in QSignal::signal () from /usr/lib/libqt-mt.so.3
#52 0xb712c8ea in QSignal::activate () from /usr/lib/libqt-mt.so.3
#53 0xb7134300 in QSingleShotTimer::event () from /usr/lib/libqt-mt.so.3
#54 0xb70a3b88 in QApplication::internalNotify () from /usr/lib/libqt-mt.so.3
#55 0xb70a59b7 in QApplication::notify () from /usr/lib/libqt-mt.so.3
#56 0xb77ccdb2 in KApplication::notify () from /usr/lib/libkdecore.so.4
#57 0xb7036389 in QApplication::sendEvent () from /usr/lib/libqt-mt.so.3
#58 0xb70965d3 in QEventLoop::activateTimers () from /usr/lib/libqt-mt.so.3
#59 0xb704aec5 in QEventLoop::processEvents () from /usr/lib/libqt-mt.so.3
#60 0xb70be25e in QEventLoop::enterLoop () from /usr/lib/libqt-mt.so.3
#61 0xb70be06e in QEventLoop::exec () from /usr/lib/libqt-mt.so.3
#62 0xb70a5731 in QApplication::exec () from /usr/lib/libqt-mt.so.3
#63 0x0804a0fe in ?? ()
#64 0xbf9f53a4 in ?? ()
#65 0xbf9f539c in ?? ()
#66 0x00000000 in ?? ()

Using imap.

Shell says "terminate called after throwing an instance of 'std::bad_alloc'"

Looks like it uses up all my memory (700MB) or something crazy. Surely it doesn't need that much to send a 50MB file? And it shouldn't crash anyway.