I believe 23805 is unrelated to my problem, and may even be invalid.
Mine comes from CharChunk.  To refresh the memory, the stack trace is

Servlet.service() for servlet jsp threw exception
java.lang.IndexOutOfBoundsException
        at sun.nio.cs.StreamEncoder.write(StreamEncoder.java:132)
        at java.io.OutputStreamWriter.write(OutputStreamWriter.java:191)
        at org.apache.tomcat.util.buf.WriteConvertor.write(C2BConverter.java:228
)
        at org.apache.tomcat.util.buf.C2BConverter.convert(C2BConverter.java:120
)
        at org.apache.coyote.tomcat5.OutputBuffer.realWriteChars(OutputBuffer.ja
va:606)
        at org.apache.tomcat.util.buf.CharChunk.flushBuffer(CharChunk.java:463)
        at org.apache.coyote.tomcat5.OutputBuffer.flush(OutputBuffer.java:357)
        at org.apache.coyote.tomcat5.CoyoteWriter.flush(CoyoteWriter.java:117)
        at org.apache.jasper.runtime.JspWriterImpl.flush(JspWriterImpl.java:203)
        at org.apache.jasper.runtime.JspRuntimeLibrary.include(JspRuntimeLibrary
.java:990)
...

In my case, it's not the offset, but "end" that is too big.  It got the value
of 16384 when "limit" is only 8192.

I have looked into this more without getting more insight.  I use jdb to
catch IndexOutOfBoundsException but couldn't figure out what caused "end"
to get this big.  Since this happens randomly, I cannot stop a thread and
follow its progress.  Inserting prints in CharChunk was also not useful,
since values for "end" in threads appear normal until the exception
occurs, as if its value were clobbered by a strayed pointer (like in C).
The print did show that in some cases, the value for "end" is 16384 after
write(char[]) was invoked, though that didn't cause any exception for some
reason.

This turns out to be more elusive that it appears.  I might have to give
this up as another mystery of the universe.  :-)

-Kin-man

> Date: Wed, 15 Oct 2003 10:36:01 +0200
> From: Remy Maucherat <[EMAIL PROTECTED]>
> Subject: Re: [5] IndexOutOfBoundsException from CharChunk
> To: Tomcat Developers List <[EMAIL PROTECTED]>
> 
> Kin-Man Chung wrote:
> > I don't know much about the test; it is one of stress test we have, but it
> > should not affect CharChunk this way, right, even if it has something
> > weird?  Like I said, this happens only in this test, and not always
> > reproducible, so I am not surprised that nobody noticed it in 4.1.  I
> > thought it might be thread related, but each thread should have its own
> > CharChunk instance, so I can't see how.  I look into this more and report
> > back.
> 
> Bug 23805 could be related to this, and I'm awaiting more details. At 
> least, the offset numbers do match, which is too big a coincidence ;-)
> 
> Remy
> 
> 
> 
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