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I know you have a solution, but the fundamental problem with most browsers is that if it thinks it can display the file (html, jpeg, txt) then it will. If it doesn't know how then it will offer to download / store the file (zip, doc, xls etc).
pdf is a slightly grey area depending upon whether you've got the reader installed, but I guess 99% have. You can always save the file once the reader has displayed it.
So the trick to force a download is to get your file in a format (with an extension) that browsers won't / can't display.
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