Email template 80% correct but then includes form variable

I have a very large form which has workwed well over the last few weeks, I add some additonal items to the form (custom code) and updated the email template (autop generate).

When happens is as follows:
[list]User completes the form[/list]
[list]The user completes captcha[/list]
[list]User submits form[/list]
[list]Form is emailed (HTML) to the admin and end user[list]
[list]Since the update, about 80% of the emailed form is correct but then the forms then includes all of the variables - whihc iof blank should not display - as they do for the majority of the form[/list][/list][/list]

I have tried reworking the form but with no luck. Is there some kind of limit I have encountered. Would shrinking the overall form help (reducing length of the variables)?

Hi Vem427,

From your description I'd guess that there is a little bug in the custom code that you added that is breaking something . . .

Bob

Happy to let you have the custom code, been through it many times now and can find no error. It isn't complicated jsut large.

Hi Vem427,

Hmmm . . . it is big :-)

I used your code to create a little test form and found that on my site the form submission cut off after 996 variables - the last entry is [HSM_Still_Water_1_5_L_Mon]

This suggests to me that it is hitting a PHP server limit, on my site suhosin.post.max_vars is set to 1000 box this would be my first check. There's also a max_input_vars setting in recent versions of PHP. Please see this FAQ, usually this is a back-end problem, yours is the first form I've seen with a size problem in the front-end.

Bob