Sorry for getting back so late. I had actually fixed the problems later in the evening of the day it started.
I had deduced that some template file had been broken so that mail was being sent to nonexistant addresses based on the variable name.
I'd get errors from /var/log/qmail/current saying:
@40000000437a08813084305c starting delivery 343970: msg 7733251 to local alias-localdelivery-if_($EmailForward_eq_"local")@ckua.com
@40000000437a088130843c14 status: local 2/10 remote 0/20
@40000000437a08813085c69c starting delivery 343971: msg 7733251 to local alias-localdelivery-____elsif_($EmailForward_eq_'forward')@ckua.com
@40000000437a08813085d63c status: local 3/10 remote 0/20
@40000000437a08813085da24 starting delivery 343972: msg 7733251 to local alias-localdelivery-____elsif_($EmailForward_eq_'both')@ckua.com
@40000000437a08813085de0c status: local 4/10 remote 0/20
@40000000437a08813088b49c starting delivery 343973: msg 7733251 to local alias-localdelivery-____elsif_($EmailForward_eq_'procmail')@ckua.com
@40000000437a08813088bc6c status: local 5/10 remote 0/20
@40000000437a0881308af6bc starting delivery 343974: msg 7733251 to local alias-localdelivery-____else@ckua.com
@40000000437a0881308afaa4 status: local 6/10 remote 0/20
@40000000437a0881308d63d4 starting delivery 343975: msg 7733251 to local alias-localdelivery-_#_Vacation_Message_Disabled@ckua.com
So obviously it was getting these email addresses from a template file directly. Big mess.
The solution at the time was to shut down smtpfront and qmail. Remove all files from the queue so I could sort the junk out and reinject outbound mail or copy inbound mail to the user's Maildir/new directory. I then grabbed a backup of the contents of /etc/e-smith and placed it back on the server.
Restarted the smtp services and everything was go.
Now all of the sudden the server-manager wouldn't let me in regardless of the source IP. In the end what happened was a flub in the restoration process of the backup.
The backup server is running Mandriva Linux and I rsync anything I wish to back up. With e-smith most user and group id's are in the 5000+ range. When copying to the backup server the gid was maintained. Unfortunately when I copied back to e-smith two directories had changed their group name from admin to rpm because gid 101 on the Mandriva box belonged to... you guessed it, rpm. chgrp -R admin to the problem directory fixed that.
Now the server-manager is backup, I had to click on every individual username and then save to reset the procmail rules.
So the conclusion I've come to is the lat-procmail tool doesn't work for me with my configuration. Secondly I have to redo some aspects of my backups, and thirdly that clicking on auser names, then save, wait for the user page to refresh and click on the next user - over 75 times takes up most of an hour.