[...]
Now here is the thing. The PerlHeaderParserHandler executes TWICE for every request. The second time through is apparently a different Apache
Could it be that something in your code pushes the handler on the stack again?
I'd suggest debugging with Apache::ShowRequest? http://search.cpan.org/author/DOUGM/Apache-Module-0.11/lib/Apache/ShowRequest.pm
Do tracing: http://perl.apache.org/docs/1.0/guide/debug.html#Debug_Tracing Use the 'h' setting PerlSetEnv MOD_PERL_TRACE h
Try to use $r->get_handlers() and see what you get.
Finally, if nothing helps, go with gdb.
Also what happens if you don't use Apache::Request?
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