Have been outputting pdfs for a while and this is what works for me ...
  
note, I don't close the pdf    pdf.close? but this allows the user to 
either open or save the file anywhere on their machine (Linux and Windows)

    
    ....
    pdf.cell( ln=0, h=9.0, align='R', w=178.0, txt="%s %s" % (euro(), 
'{:10,.2f}'.format(inv_tot)), border=0 )

    import os
    import sys
    if session.inv_print_type == 'ORIGINAL':
        invc_filename = "INVC_%s_%s.pdf" % 
(session.inv_number,session.inv_company)
    else:
        invc_filename = "INVC_%s_%s_COPY.pdf" % (session.inv_number, 
session.inv_company)

    invc_filename = invc_filename.replace(' ','_')
    invc_filename = invc_filename.replace( '&', 'and')

    s_io = pdf.output(dest='S')
    response.headers['Content-Type']='application/pdf'
    response.headers['Content-Disposition'] = 'attachment; filename="%s"' % 
invc_filename
    raise HTTP(200, s_io, **response.headers)

>
>
>

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