Malformed Header with Apache2 + FCGI

Once again with feeling…

Environment is Suse 9 + Apache2 + fcgi + oracle + rail 0.14 + ruby 1.8.

Everytime I restart apache on this box and hit the site I get the
following
error in the log:

FastCGI: comm with server /home/www/myapp/public/dispatch.fcgi aborted:
error
parsing headers: malformed header ‘Config arg usernameBubba’.

Hittting refresh in the browser once more correctly displays the page.
Same thing happens by killing the dispatch.fcgi processes…

Anyone ran into this predicament ?
What magic spell or incantation release this curse ?

Thanks to all…