nice of you to write up the solution...

Matthew North wrote:
>  Thanks to all who responded.  Your responses reconfirmed that there
>  must be some configuration difference between the two so I grudgingly
>  re-examined everything, and esp. phpinfo() output.
>  
>  Turns out the test machine had a default (at build time) of
>  'output_buffering = 0'.  Although the two machines shared exact
>  php.ini, the test machine was effectively doing no output buffering
>  while the development system was.  Explicitly changing this setting to
>  4096 'solved' the problem.
>  
>  However, this wasn't the whole story.  Turning on output buffering
>  could only solve the problem if we were doing some out-of-band output
>  before the session headers were sent that was now being buffered.
>  Sure enough I found some code that was outputting some response text
>  before session_start() was called.  On the test machine this output
>  was being buffered until after session_start(), so no apparent problem
>  existed.
>  
>  I think the lesson here is, if you're missing headers in your output,
>  assume first that it's because you've started body output before the
>  headers in question were sent.  If I'd made that assumption earlier I
>  probably would have saved hours on this bug!  (otoh, doesn't that
>  situation normally result in a PHP warning?  where'd that go?  oh
>  well...).

most likely ini setting display_errors is OFF - chances
are the PHP errors/warnings/etc are being logged to the apache error log.

>  
>  - Matt
>  

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