WP CheckUp - screen, email and PDFs all different

Hi.

On screen, I get http://d.pr/f/7rCq (proper result)
If I click send as email, I get http://d.pr/f/CafR (blank file)
If I click download as PDF, I get http://d.pr/f/jIT5 (100% pass!!)

Thoughts?!!

Rich.