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That sounds too familiar. I was baffled for a long time until I found mention of it previously in this forum that is was Symantec Endpoint Protection (SEP). I had trouble recreating it myself until I realized that it required opening the attachment in the composed email before sending it.
I am not familiar with excluding attachment types from SEP to know if that prevents SEP from modifying the email. You might want to check. Via the Notes client does the problem email (the email before sending, in Sent or the received email) document properties (Alt-Enter, second tab) have 4 LastScan* fields? If so, SEP is still affecting it.
As you probably know, starting with SEP 11.0.70xx those fields are added when the attachment is opened in the Notes client. In this case they are added when the sender opens the attachment before sending the email. If those fields have non-readable data, the error can occur in iNotes for the recipient. The non-readable field data problem is fixed in SEP 11.0.72xx. I know the problem also occurs in SEP 12.1.11xx. The beta for 12.1.20xx looks promising.
As for solutions if it is SEP, do not open the attachment before sending, remove the SEP Notes scanner or install a version of SEP that does not add non-readable data.
Feedback response number WEBB8YAG2G created by ~Umberto Lopluplopflar on 09/19/2012