There's a very nice PHP interface to PDFlib. See
http://www.php.net/pdf . Once you've got that going, it's just some trial and error to get the layout to be acceptable.
Little secret: if you generate HTML, put a .doc extension on it, and send it down with the MIME type "application/msword", it'll open just great in recent enough versions of Word. It won't load external images, but it'll do anything you can do in HTML.