I figured out what it was.  One of the $r->header_in() was trying to
insert an Authorize header, and I didn't notice that base64_encode()
tacks on a newline.

After Apache core got thru with it, it ended up looking like:

        Authorize: Basic ....\n
        \r\n
        \r\n
        <parameters>

which caused the destination server to start parsing the parameters two
characters early, hence the last parameter had two characters lopped off
the end.

Sigh.

Thanks all.

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