The dropped connection problem appears even with emails as small as 15 megs. Unless I'm missing something, that's well short of the 50 meg limit here even considering BASE64 attachment overhead. I think we need to keep looking for a cause.
Often times my sendmail MTA can't deliver large emails (15+ megs) to a receiving MTA. Here's an example of what the log says when the attempt fails:
Aug 11 14:45:18 mail sm-mta[31009]: q76M18iZ014587: to=<vran2@unitedfresh.org>, delay=4+23:44:10, xdelay=00:21:57, mailer=esmtp, pri=28052803...
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