This bug still exists in v3.2.4.  I have been able to get more information on 
why it occurs on some of our systems but not on others.

The Perl executable is installed in /usr/local/bin with a symlink 
from /usr/bin:

lrwxrwxrwx   1 root           19 Jul 18  2005 /usr/bin/perl -
> /usr/local/bin/perl
-rwxr-xr-x   2 root      1141560 May 10  2007 /usr/local/bin/perl

If the PATH has /usr/local/bin before /usr/bin, then the spamd_hup test runs 
without error.
If the PATH has /usr/bin before /usr/local/bin, then the spamd_hup test fails 
as shown above.

I think that the problem is in this section of spamd:

  my $perl = Mail::SpamAssassin::Util::untaint_var($^X);
  my @execs = ( $perl, "-T", "-w", $ORIG_ARG0, @ORIG_ARGV );

  if ($perl eq $perl_from_hashbang_line) {
    # we're using the same perl as the script uses on the #! line;
    # we can safely just exec the script
    @execs = ( $ORIG_ARG0, @ORIG_ARGV );
  }

  warn "spamd: restarting using '" . join (' ', @execs) . "'\n";
  exec @execs;

When /usr/bin comes first in the PATH, the block controlled by the "if" is 
executed.  Since the "-T" switch is NOT saved in @ORIG_ARGV, the exec goes 
boom.  I don't know the best way to fix the problem, but it seems like leaving 
out the "if" block will fix it.

Solaris 10, Sa 3.2.5, OS installed perl 5.8.4

bug is still there:
$ tail t/log/d.spamd_hup/spamd.err.1
[10866] warn: spamd: restarting using '../spamd/spamd.raw -D -x -s stderr -C log/test_rules_copy --siteconfigpath log/localrules.tmp -p 43630 -A 127.0.0.1 -L -r log/spamd.pid -s log/d.spamd_hup/spamd.err.1.timestamped'
syswrite() on closed filehandle STDLOG at ../blib/lib/Mail/SpamAssassin/Logger/File.pm line 81.
Too late for "-T" option at ../spamd/spamd.raw line 1.


completes test just fine:
/usr/perl5/5.8.4/bin/prove -v t/spamd_hup.t
...
Files=1, Tests=110, 46 wallclock secs (14.79 cusr +  1.62 csys = 16.41 CPU)

needs a quick triage for 3.3.0.

so -- I can't reproduce this now on Solaris 10 with 3.3.0. I'm going to move it off the milestone, but pipe up if it's still happening with that code....

it's still here for me:

$ wget http://people.apache.org/~jm/devel/Mail-SpamAssassin-3.3.0.tar.bz2
$ bzip2 -dc Mail-SpamAssassin-3.3.0.tar.bz2 | tar -xf -
$ cd Mail-SpamAssassin-3.3.0
$ echo | perl Makefile.PL && make
$ cat t/config.dist | sed 's/run_long_tests=n/run_long_tests=y/' > t/config # else it will be skipped by 'make test'

$ make test TEST_FILES="t/spamd_hup.t"
/usr/bin/perl build/mkrules --exit_on_no_src --src rulesrc --out rules --manifest MANIFEST --manifestskip MANIFEST.SKIP
no source directory found: exiting
/usr/bin/perl build/preprocessor  -Mvars  -DVERSION="3.003000"  -DPREFIX="/usr/perl5/5.8.4"  -DDEF_RULES_DIR="/usr/perl5/5.8.4/share/spamassassin"  -DLOCAL_RULES_DIR="/usr/perl5/5.8.4/etc/mail/spamassassin"  -DLOCAL_STATE_DIR="/usr/perl5/5.8.4/var/spamassassin"  -DINSTALLSITELIB="/usr/perl5/site_perl/5.8.4"  -DCONTACT_ADDRESS="the administrator of that system" -Msharpbang  -Mconditional  -DPERL_BIN="/usr/bin/perl"  -DPERL_WARN=""  -DPERL_TAINT="" -m755 -isa-update.raw -osa-update
cp sa-update blib/script/sa-update
/usr/bin/perl "-MExtUtils::MY" -e "MY->fixin(shift)" blib/script/sa-update
PERL_DL_NONLAZY=1 /usr/bin/perl "-MExtUtils::Command::MM" "-e" "test_harness(0, 'blib/lib', 'blib/arch')" t/spamd_hup.t
t/spamd_hup....ok 1/110# Failed test 5 in t/spamd_hup.t at line 40           
#  t/spamd_hup.t line 40 is:   ok (-e $pid_file) or warn "$pid_file does not exist post restart";
log/spamd.pid does not exist post restart at t/spamd_hup.t line 40.
t/spamd_hup....NOK 5/110Could not open pid file log/spamd.pid: No such file or directory
t/spamd_hup....ok 6/110Exiting subroutine via next at t/SATest.pm line 890.  
Could not open pid file log/spamd.pid: No such file or directory
Exiting subroutine via next at t/SATest.pm line 890.
Could not open pid file log/spamd.pid: No such file or directory
Exiting subroutine via next at t/SATest.pm line 890.
Could not open pid file log/spamd.pid: No such file or directory
Exiting subroutine via next at t/SATest.pm line 890.
Could not open pid file log/spamd.pid: No such file or directory
Exiting subroutine via next at t/SATest.pm line 890.
Could not open pid file log/spamd.pid: No such file or directory
Exiting subroutine via next at t/SATest.pm line 890.
Could not open pid file log/spamd.pid: No such file or directory
Exiting subroutine via next at t/SATest.pm line 890.
Could not open pid file log/spamd.pid: No such file or directory
Exiting subroutine via next at t/SATest.pm line 890.
Could not open pid file log/spamd.pid: No such file or directory
Exiting subroutine via next at t/SATest.pm line 890.
Could not open pid file log/spamd.pid: No such file or directory
Exiting subroutine via next at t/SATest.pm line 890.
t/spamd_hup....FAILED tests 5, 7-110                                         
        Failed 105/110 tests, 4.55% okay
Failed Test   Stat Wstat Total Fail  List of Failed
-------------------------------------------------------------------------------
t/spamd_hup.t              110  105  5 7-110
Failed 1/1 test scripts. 105/110 subtests failed.
Files=1, Tests=110, 63 wallclock secs ( 0.83 cusr +  0.25 csys =  1.08 CPU)
Failed 1/1 test programs. 105/110 subtests failed.
*** Error code 29
make: Fatal error: Command failed for target `test_dynamic'


completes test just fine:
/usr/perl5/5.8.4/bin/prove -v t/spamd_hup.t
...
All tests successful.
Files=1, Tests=110, 45 wallclock secs ( 8.98 cusr +  2.96 csys = 11.94 CPU)

Same problem with AIX. /usr/bin/perl was symbolically linked to /usr/opt/perl5/bin/perl5.8.8 and /usr/opt/perl5/bin was not in $PATH. A fast work around for me was to temporarily put /usr/opt/perl5/bin as the first dir in $PATH, remake spamassassin. make test for spamd_hup.t then passed.

make install worked normally and I put /usr/opt/perl5/bin in my PATH. spamassassin --lint doesn't complained and that is as far as I am at this writing.

(In reply to comment #6)
> Same problem with AIX. /usr/bin/perl was symbolically linked to
> /usr/opt/perl5/bin/perl5.8.8 and /usr/opt/perl5/bin was not in $PATH. A fast
> work around for me was to temporarily put /usr/opt/perl5/bin as the first dir
> in $PATH, remake spamassassin. make test for spamd_hup.t then passed.
> 
> make install worked normally and I put /usr/opt/perl5/bin in my PATH.
> spamassassin --lint doesn't complained and that is as far as I am at this
> writing.

Closing as a system configuration issue.