Tracked this down to a problem with x_sendfile - i needed to set it to 
false in order to get it working.  Here's my current call:

  render_pdf :template => 'school_subscribers/show_pdf',
             :send_file => { :filename => filename,
                             :x_sendfile => false,
                             :disposition => "inline",
                             :type => "application/pdf"}

I don't know why x_sendfile is going wrong - it misbehaves the same way 
in my local single mongrel setup, my local apache&mongrel setup and our 
staging server which is apache with multiple mongrels.  I don't know 
much about x_sendfile but even my much more knowledgeable colleague is 
stumped.
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