I'll have to agree with doulos8. The click here to download, then in some browsers click another link to get it to doewnload, then open the PDF (that's always harder to workwith/read than an HTML page) gets really tiresome. I'm always happy when a download has the "also available as an article" link. Why aren't all downloads available as HTML?
If you all are trying to make select content only available to registered users, I'd hope that your logon popup would work for HTML pages as well as downloads.
If you all are trying to make it easier for us to download and print out helpful hints, then perhaps you should go with a separate print CSS. Worse case senario, post all the downloads as articles and then have a button/link at the bottom of the article to "download this helpful article as a PDF". I'd bet the majority of your visitors like to immediately scan an article in HTML and then decide if they'd like to go through the trouble of downloading it or not.
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