Hi Louie,

> > Content-Type: pdf; name="Solutions.pdf"

I believe there is no mime type called "pdf". The normal mime type for
pdfs is "application/pdf". This may be all that is messing up things
for you.

It is a bit strange that your pdf has this mime type since Cake's
EmailComponent looks to output a simple "application/octet-stream"
which basically tells the receiving end "Binary data... you figure out
what it is!" So yoyr problem may be that Yahoo has problems with
"generic" attachments... but that is also a bit strange since they are
not exactly a recent startup, new to the web :)


> Hmm.. This looks kinda simple, but does CakePHP has this feature?
> where I could tell that this is base64? I checked the API and I could
> not find any. Only a header() option.

You can simply check that is is a correct base64 by copying the data
and pasting it into a string and running it through base64_decode().
You should see a lot od binary crap returned but outputting it to a
file from php should yield a working pdf... hopefully. It is a lot
simpler with images since they usually contain an readable identifier
at the beginning of the file... like "GIF89a". Pdfs only occasionally
contain this kind of string.

If you want to try yet another package: I have used the PEAR Mail_Mime
package with success.
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