Jonathan,

> It seems that amavisd isn't properly looking inside of "rar" attachments
> in our configuration.  The unrar binary is detected on startup as the
> application to deal with rar archives, but nothing is (seemingly) done
> with these archives when a message passes through the system.
>
> I can successfully unrar stuff using the binary on the command line
> (unrar e <filename>), and other archive utilities seem to be working
> well.  Problem seems to occur with numerous versions of amavisd-new
> (2.3.2, 2.5.2, 2.6.1).

> Log snippit from message containing test.rar (which contains a (banned)
> .exe file):

> Oct 23 13:31:23 iscan1 amavis[22296]: [ID 702911 local1.info] (22296-01)
> p002 1/2 Content-Type: application/octet-stream, size: 64622 B, name:
> test.rar

So the p002 part is of interest here.
Let's see what the file(1) utility makes of it:

> Oct 23 13:31:24 iscan1 amavis[22296]: [ID 702911 local1.info] (22296-01)
> run_command: [22336] /usr/bin/file p001 p002 </dev/null 2>&1

> Oct 23 13:31:24 iscan1 amavis[22296]: [ID 702911 local1.info] (22296-01)
> result line from file(1): p002:\t\tdata

It says 'data', not 'RAR archive data'.
So either the part is not a recognizable RAR archive,
or your file(1) utility is broken.

RAR decoding would only be invoked on parts which the file(1) utility
recognizes as a RAR archive. (with the exception of executables
which are tested for being self-extracting archives).

  Mark

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