I don't pretend to know what is going on, but as I was bored, here are a couple of things that I did to your code, and I did end up with a functioning PDF:

• use non-interlaced PNG with $image->interlaced(undef); in the PNG sub
• throw in a $hPdf->save; at the end of the PDF sub
• make sure your media box is large enough (at least 800x600 in your case)

Hope this helps!

Update: Versions I used (:

• Perl 5.8.3 as ActiveState build 809 on Win2k
• GD::Graph::bars 1.25
• PDF::API2 0.3r77

It also appears that the stringify is messing things up - either put the save before it or just remove it altogether as it serves no useful purpose (at least in this code fragment).

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