Annoying platform problems solved
The problems with Windows continue, this time with the PDF generation, which depends on FOP being able to find the TTF font files. The trailing-slash issue seemed to be at the heart of it, but then I discovered that there was also an issue with the root path containing backslashes, but the relative path component for fonts having forward slashes.
After much pain and suffering, looking for a way to determine what host os Cocoon is running on, I decided that I can make that decision based on the presence of backslashes in the root path. If there are backslashes, then I conclude that it's running on Windows, so I need to change forward slashes to backslashes, and make sure the trailing slash is added to the end of the root path.
This is done in the file:
fop-config.xsl
Tomorrow, I'll try migrating this solution to the live server, with the usual caution.