I'm new to perl, but I used your script as the basis for my own, which looks for a line break and then a word break to optimize space without cutting out mid-word. Limitations: The title has a max length of 15 chars (107 bytes for markup + 3954 for text = 4051 bytes; title is repeated in 3 markups).

unless (@ARGV) {
print "Usage: $0 <filename(s)>\n";
exit(1);
}

foreach my $file (@ARGV) {
if (-f $file) {
print "$file exists.\n";
&chopfile($file);
} else {
print "$file not found.\n";
}
}

sub chopfile {
my $filename = shift;
open(my $longfile, "<", $filename) || die ("can't open $filename");
my @arr = ();
my $len = 0;
my $i = 0;
print "Title:> \n";
my $title = <STDIN>;
chomp($title);
mkdir($title);
chdir($title);
while (<$longfile>) {
my $trylen = length($_);
if (($len + $trylen) <= 3954) {
push(@arr, $_);
$len += $trylen;
} else {
my $diff = 3954 - $len;
my $addme = substr($_, 0, rindex($_, " ", $diff));
my $addmelater = substr($_, (rindex($_, " ", $diff) + 1));
push(@arr, $addme);
open(my $output, ">", $title.$i.".txt");
print $output "<?xml encoding=\"utf-8\"?>\n";
print $output "<TITLE>".$i." ".$title."</TITLE>\n";
print $output "<A HREF=\"".$title.($i-1).".txt\" NOPUSH><</A>\n" unless ($i == 0);
print $output @arr;
print $output "\n<A HREF=\"".$title.($i+1).".txt\" NOPUSH>></A>";
close $output;
@arr = $addmelater;
$len = length($addmelater);
print $title.$i." created.\n" if (($i % 10) == 1);
$i++;
}
open(my $output, ">", $title.$i.".txt");
print $output "<?xml encoding=\"utf-8\"?>\n";
print $output "<TITLE>".$i." ".$title."</TITLE>\n";
print $output "<A HREF=\"".$title.($i-1).".txt\" NOPUSH><</A>\n" unless ($i == 0);
print $output @arr;
close $output;
}
}

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