OK, since no-one has come forward with any suggestions, here is my latest update.
Tried ABC Amber Text Merger to make pdf / rtf from the wikipedia cd files on my hard disk. The Merger has a "number of files" limitation, so it could not add all the wikipedia CD files at once - crashed, saying index out of range. So, went back to letter-by-letter. Found it to be slower than HTML2LRF and also the output was uglier. Also, file size for wpcd_a.rtf was 23 MB while the html files in the folder totalled only 5 MB.
Tried other pdf tools, like pdf995. Did not create clickable links.
So I will make the HTML2LRF concatenations for each alphabet and post the links here.
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