Rails - Aug 2009 - Anyone used acts_as_flying_saucer? problem with pdf_file

hey all

I''m trying to use the plugin acts_as_flying_saucer, which converts html
(well, xhtml, strictly speaking) to pdf.
http://github.com/dagi3d/acts_as_flying_saucer/tree/master

It works if i choose the method which saves a file to my local hd, but
it doesn''t work if i choose the method which sends a file to the
browser: the file that comes through has a size of 1 byte and can''t be
opened.

I''m following the examples on the above page and as far as i know have
checked all the right boxes.  Here''s my code -

This works:

        render_pdf :template =>
''school_subscribers/show_pdf'',
                   :pdf_file =>
''/home/max/Desktop/saved.pdf''

And this doesn''t work (sends an empty file):

        render_pdf :template =>
''school_subscribers/show_pdf'',
                   :send_file => { :filename => "pushed.pdf" }

Does anyone have any experience with, or insight into, this by any
chance?

thanks
max
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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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