Thanks for yourr response Scott.
I was hoping for something native, I haven't used apex for many years now, so forgot almost about it.
I am happy to drop the PDF altogther if I can produce a nice pritable page in HTML without the menu/toolbar and it can be sent as an email. I noticed interactive reports has a bit of this funtionality but I just wanted some guidance on how to produce a nicely looking page.
You can natively produce PDFs from IR with ORDS (acronym city!), but the output is fairly basic, with limited configuration options.
If a printable page is all you're after, then the PRINTER_FRIENDLY parameter could help (by adding conditions to things), along with some CSS media queries.
There are also a few CSS attributes targeting printing.