So why not copy and paste the contents of the email into an 'Office' document and then convert to PDF for printing?
He has already done this and said it worked perfectly.
I think the OP is making this harder for himself than it needs be.
If your email is blowing out to 500 pages, then you are dealing with raster data and spooling.
Without going right into it, can you Print directly to the printer?
You would have to go into Advanced Options.