I figured this out and figured I'd post to help anyone else who comes along this problem. Not sure how these settings got in the config after the update, but there were additional settings overriding my final_bad_header_destiny = D_PASS;
Code:
%final_destiny_by_ccat = (
CC_VIRUS, D_DISCARD,
CC_SPAM, D_DISCARD,
CC_BANNED, D_BOUNCE,
CC_OVERSIZED, D_BOUNCE,
CC_BADH.',4', D_BOUNCE,
CC_BADH.',3', D_BOUNCE,
CC_BADH, D_PASS,
CC_UNCHECKED, D_PASS,
CC_CLEAN, D_PASS,
CC_CATCHALL, D_PASS,
);
This little nugget was also in there and was bouncing the bad header emails. Removed the CC_BADH.',4', D_BOUNCE, and CC_BADH.',3', D_BOUNCE, to fix.