I tried adding:
        response.headers['Cache-Control']="private"
        return response.stream(pdfContents,chunk_size=4096)

based on this thread: 
http://groups.google.com/group/web2py/browse_thread/thread/8da2043ec17debd6/4ae69758b19ba426

That solves the issue as well, without the need for patching main.py.
I am still in the dark about why
web2py seems to be streaming an HTML reply first...

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