Email PDF from Mail Merge Problem

Using a data source of email addresses from Excel 2003 and performing a mail merge in Word 2003 with the Mail Merge to Adobe PDF button, everything worked okay and the emails generated to the outbox in Outlook 2003 with the relevant PDFs attached.  However, once they were mailed the recipients who use Outlook Express had the attachments missing.  I'm using Acrobat 8.1.5
I've seen previous queries about this and it seems to relate to Outlook using a RTF format.  I set Outlook to default to html and then plain text formats but still had the same problem. Can anyone suggest how I can solve this or if the problem is Outlook related, then another email program that would work without causing this problem (preferable freeware or inexpensive).
Thanks

Just an interesting after thought, since you mentioned blocking. Several federal agencies and companies block zip files also. I ran onto a message recently about the university blocking zip files at one time because of a problem. Mail merge files are typically personalized and it would be nice for them to go intact. If they re not personalized, but just being sent in general, then posting the basic file and e-mailing a link might work better. For a lot of things I do, I just use the mail merge that is built into my e-mail client. That creates a mail-merge of messages that are personalized.
Just thought the blocking comment might be of interest, though I give the same advice. I am not sure how it could be done with zip in a mail merge sense.

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