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The reason why commenting out var_dump was needed is that it sends "headers" to the browser and so you cannot then resend headers!
I've found that sending pdf's to browsers can be a bit hit and miss with IE - sometimes it spews the pdf code rather than the document particularly if refresh is pressed, so I use
Thanks for the tip. I'm going to play with it some more....while testing various combinations, I did discover the joy of watching the browser window fill up with basically a bunch of garbage.....