The download.php should be placed in your vb folder (can be placed elsewhere, but then you would need to change the require('./global.php'); line a bit). The actual download material files should be placed in a non web accessible location; and that location is specified on top of the download.php file.
Hmm, pdf files... sorry i can't really think of much. It could be something with web server configuration, could be just how PDF files are made - most likely the former though. If someone can confirm that, it would be nice. For the time being it might be a good idea to just zip them (the file will provide a download box either way and not show it in the browser, so might as well cut down the download size a bit).
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