OK, ended up delving into things myself and although I have committed the 
cardinal sin of hacking the core, I got things working as I needed:

I got inspiration from:
http://ask.cakephp.org/questions/view/dynamic_creating_a_pdf_and_send_as_attachment
 

And here's a pastbin of the modificaions I made:
http://bin.cakephp.org/saved/72500 

This allows me to add dynamic attachments using the following:
$email->attachments('invoice.pdf'=>array(
  'url' => '/bookings/invoice/'.$id,
  'ext' => 'pdf',
  'dynamic' => 1
)

Would love someone to have a look at the changes and suggest how I could do 
this in a less hacky way.

HTH, Paul

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