Have been rethinking the PDF
I've been doing that for the newsletter so I can have some control over the formatting. And it's just plain easier dropping images and links into it. The system I'm using does include the option for TinyMCE for writing, so I might give that a shot, and just do a rich HTML-formatted email.
I've been avoiding that because I get all my mail in plain text by default, and only download images or HTML when I need it. Just because I do that doesn't mean most of the people on my list do it.
As for how I send, it's individual mails to each recipient. My host counts each address as one outgoing message against my quota anyway, so doing the BCC route wouldn't save me much anyway.
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Drew