Bottomline PrecisionForms Email: File Did Not Contain an Email Header

Bottomline PrecisionForms is a powerful tool for formatting and delivering beautiful reports and forms (invoice, PO, BOL, RFQ...) from Dynamics AX.  I have been using this tool for almost ten years now.  You might encounter the following issue when setting up the Bottomline PrecisionForms Email server.

File did not contain an email header or errors were encountered.

First step is to review the spooler file which the printer was trying to process:

C:\Bottomline Technologies\PrecisionForms\spool

As shown in the screen shot, the file is a PDF file with a .tmp extention.  The way that PrecisionForms knows where to send the file is that it will add some text within the .tmp file with the email details.  These details should be passed from the Director project as part of resubmitting to a different queue.  The director project confirms it should be filled out:

The fix?
Open PrecisionForms Email and configure the email queue's default project and change the default merge configuration to "PDF with Job Ticket."