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The format has to be PDF because of all the graphics and unusual fonts in the 104-page document.
I can find a ton of compilers that will handle downloads using HTML and .exe files.
I'm concerned about security for the download also.
Does anybody know of a good app?
Browsers will use helper apps to display the PDF in the browser, even if you change the file extension. You will need to feed the file to the browser with a munged content-type header to force it to download. Recently discussed here [webmasterworld.com].
Also touched on in that thread is a method of securing the download. You will need php, perl, or other server-side scripting skills to do this, as well as connect ot a payment processor - which answers your question, there are no free canned applications you can get for free to do this.
However I've programmed this exact same scenario quite a few times. :-)