Exchange 2003 to 2007 or 2010 generates the BFF9FFFF when it cannot understand the translation between an Bridgehead and CAS. If you manually telnet to the SMTP of the old 2003 Front-End try emailing the mail-enabled PF, it will work. This is due to the CAS being excluded. You should be able to get around this issue by replicating the 2003 folder to the 07/10 server. Once if fully replicates the CAS server will no longer create the error. Hopefully this helps with some of the discussion.
For the other part of the discussion on the TO line, you need to create a hub transport rule to remove the To header from the emails. It may be a pain, but I believe I read somewhere that this is a known bug.