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A bunch of questions.  You seem to have narrowed this
problem down a lot, but I'm not sure I understand the diagnosis.

First off, have you tried the latest version of the code
from CVS?  It has changed in several ways, so it would be
helpful if you could test with that version.  I've been
running a test driver for about an hour now without seeing
any errors caused by httplib.

The real problem I have is understanding what path through
the code leaves chunked set to a true value and chunk_left
set to something invalid.
The begin() method of an HTTPResponse always sets chunked to
1 or 0.  If  it sets chunked to 1, it sets chunk_left to None.