Thanks for the replies, and sorry for not showing the code. I had the 
following code in a dhandler that was causing trouble with IE:

<%args>
$arg1 => ''
</%args>

<%init>
my ($order) = ($r->filename =~ /.*?\/letters\/(.*?)\.pdf/gi);
my $output = generate_pdf($order, $arg1);
#$r->content_type('application/pdf');
$m->clear_buffer;
$m->print($output);
$m->abort;
</%init>

<%flags>
inherit => undef
</%flags>

I changed the code to:

<%args>
$arg1 => ''
</%args>

<%init>
$m->clear_buffer;
my ($order) = ($r->filename =~ /.*?\/letters\/(.*?)\.pdf/gi);
my $output = generate_pdf($order, $arg1);
$r->content_type('application/pdf');
$r->headers_out->{'Content-Disposition'} =
        "attachment;  filename=$order.pdf";
$r->headers_out->set('Content-Length' => length($output));
$r->send_http_header;
$m->print($output);
$m->abort(OK);
</%init>

<%flags>
inherit => undef
</%flags>

And it still wouldn't work for IE. The error I get is:
1. File Download Security Warning - it asks if I want to download the file.
2. I click on save or open and I get the "file download" popup but I get 
another popup immediately after saying:
 "IE cannot download filename.pdf from www.domain.com. IE was not able 
to open this Internet site. The requested site is either unavailable or 
cannot be found. Please try again later."
 I click on "OK" and it aborts the download.

Now the above error always happened with a http:// request, but I found 
that it works fine if the request is https://. Go figure. So I guess 
I'll accept that and always link to it using ssl. Wonder why that is though.

Justin



Andreas Marienborg wrote:
> At work we serve custom PDF files with the following component:
>
> $m->clear_buffer;
> $r->content_type("application/pdf");
> $r->headers_out->set('Content-Length' => length($data));
> $r->send_http_header;
> $m->print($data);
> $m->abort(OK)
>
> where $data is the PDF document as a scalar.
>
> and for future questions, a code snippet might help alot in aiding you 
> better :)
>
>
> andreas
>
>
> On 27. jul. 2006, at 23.10, J Cook wrote:
>
>> I am generating a pdf on the fly and serving it up with mason, I set the
>> headers out -> content type application/pdf and this works fine in
>> Mozilla and Firefox but Internet Explorer throws an error and won't
>> proceed with the download. Anyone have any clue as to why this is?
>>
>> Justin
>>
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