You would need to stream the file content to the user while reading it from the S3 bucket/object.
If you use the AWS::S3 library something like this may work:
send_file_headers!( :length=>S3Object.about(<s3 object>, <s3 bucket>)["content-length"], :filename=><the filename> )
render :status => 200, :text => Proc.new { |response, output|
S3Object.stream(<s3 object>, <s3 bucket>) do |chunk|
output.write chunk
end
}
This code is mostly copied form the send_file code which by itself works only for local files or file-like objects
N.B. I would anyhow advise against serving the file from the rails process itself. If possible/acceptable for your use case I'd use an authenticated GET to serve the private data from the bucket.
Using an authenticated GET you can keep the bucket and its objects private, while allowing temporary permission to read a specific object content by crafting a URL that includes an authentication signature token. The user is simply redirected to the authenticated URL, and the token can be made valid for just a few minutes.
Using the above mentioned AWS::S3 you can obtain an authenticated GET url in this way:
time_of_exipry = Time.now + 2.minutes
S3Object.url_for(<s3 object>, <s3 bucket>,
:expires => time_of_exipry)