This was rather silly of me,
I was trying to add this line to my .htaccess:
RewriteRule ^free/download\.php /free/download/pdf [NC,L]
Not realizing that the Rewrite Conditions were completely negating my Rule.
The following will not Rewrite the URL if the Requested Filename is a regular file (example download.php)
RewriteCond %{REQUEST_FILENAME} !-f
The solution of course is to use the Zend Router to do the redirection, it’s one of those fore-head-smacking moments
I added this to my application.ini and away it went,
routes.freedownload.route = “free/download.php” routes.freedownload.defaults.controller = “free” routes.freedownload.defaults.action = “download” routes.freedownload.defaults.type = “pdf”