Glad to hear that fixed your problem! I've never used HTML emails for this, just plain text. I prefer that, especially for subcontractors, as they don't need anything pretty to fulfill orders! :) The PDF file is really for the customers (even though it goes to the subcontractor), so that looks a little more polished.

Hmmm... Not quite sure what you mean about the e for edit orders. The edit orders add-on is not the same as the edit orders included with Zen Cart. You might want to look into that and see what is going wrong. Still sounds like you are missing a few files in 1.3.8a. Also, try clearing your browsers cache. That might be the problem with the e.