Building on the tests with Tinderbox’s Help file, I’ve managed to repeat the process for the current aTbRef as a single PDF (562 pages, 30MB):
It the ToC is generated by Tinderbox as part of the export from aTbRef.
Apart from needing some better CSS for heading sizes (it uses H1 through H7) I think it is feature complete.
The moving parts for this aren’t in the aTbRef TBX at present. Given the scope for errors, I worked on a copy.
Is this document any use to people who want a PDF manual?