Does anyone have ideas about this before I start digging to find when
it got broken?

On -current:

| $ echo "test message" | openssl smime -sign -signer mail.cert -inkey mail.key
| Enter pass phrase for mail.key:
| MIME-Version: 1.0
| Content-Type: multipart/signed; protocol="application/x-pkcs7-signature"; 
micalg="sha1"; boundary="----D6AE072D584EB7DD96921A8B5D85CEB4"
| 
| This is an S/MIME signed message
| 
| ------D6AE072D584EB7DD96921A8B5D85CEB4
| test message
| 

i.e. no signature section.

On 5.4 :-

| $ echo "test message" | openssl smime -sign -signer mail.cert -inkey mail.key
| Enter pass phrase for mail.key
| MIME-Version: 1.0
| Content-Type: multipart/signed; protocol="application/x-pkcs7-signature"; 
micalg="sha1"; boundary="----4B2635AD8016836C6AB87A92750410E5"
| 
| This is an S/MIME signed message
| 
| ------4B2635AD8016836C6AB87A92750410E5
| test message
| 
| ------4B2635AD8016836C6AB87A92750410E5
| Content-Type: application/x-pkcs7-signature; name="smime.p7s"
| Content-Transfer-Encoding: base64
| Content-Disposition: attachment; filename="smime.p7s"
| 
| <snip 49 lines>
| 
| ------4B2635AD8016836C6AB87A92750410E5--
| 


Also with -outform DER added to the command line, on -current:

24566492045156:error:21080082:PKCS7 routines:PKCS7_dataFinal:decode 
error:/usr/src/lib/libcrypto/crypto/../../libssl/src/crypto/pkcs7/pk7_doit.c:791:
24566492045156:error:21086091:PKCS7 routines:PKCS7_final:pkcs7 
datasign:/usr/src/lib/libcrypto/crypto/../../libssl/src/crypto/pkcs7/pk7_smime.c:132:

On 5.4, binary data is output as expected.

"openssl smime -encrypt" *does* work.

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