Finally I've got a chance to analyze your problem.
The "GIF" isn't actually a GIF at all - it was the "favicon.ico" icon file - so my guess is that mod_perl is sneaking a peek at what comes next (expecting GIF89a or whatever) and doing something wrong when that 'aint it. I realize I shouldn't be saying "image/gif" in this case, but then - mod_perl shouldn't be screwing up my headers just 'coz of that mistake?
mod_perl wasn't doing anything like that. The problem was in the contents of favicon.ico. .ico files seem to start with the sequence \000\000 and mod_perl 2.0 had a bug dealing with parsing printed headers immediatelly followed by response body starting with '\0'. I've reduced your test to a one liner script:
print "Content-type: image/x-icon\n\n\000\000\001\000";
It's now fixed in the cvs.
On a personal note - I think the whole mod_perl header system should have been omitted. If a script wants to send the headers, it should be allowed to, without interference. Making people learn an indeterminate number of new custom non-standard callbacks like "content_type()" and whatever the ones are for caching, p3p, cookies, accept, encoding, charsets, and so forth is silly - since everyone who knows they're needed already knows how to send them normally - hence the extra bunch of callback stuff just wastes everyone's time. Just my $0.02...
Nobody prevents you from printing your own headers. It's just much slower. I just wrote a new docs section explaining the differences and nuances of headers generating:
http://perl.apache.org/docs/2.0/user/coding/coding.html#Generating_HTTP_Response_Headers
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