> - Have you changed the random page cost on either installation?

This is whatever the default is for both boxes (commented config file says 4.0)

> - Have both installations had VACUUM ANALYZE run recently?

This is the first thing I did and didn't seem to do anything.

Oddly enough I just went and did a VACUUM ANALYZE on a newly restored
db on the test server and get the same query plan as production so I
am now guessing something with the stats from ANALYZE are making
postgres think the string index is the best bet but is clearly 1000's
of times slower.

> - Are the stats targets the same on both installations?

If you mean default_statistics_target that is also the default
(commented config file says 10)

> - Do both installations have similar shared buffers, total available RAM 
> info, etc?

The boxes have different configs as the test box isn't as big as the
production on so it doesn't have as much resources available or
allocated to it.

I did run the query on the backup db box (exact same hardware and
configuration as the production box) which gets restored from a backup
periodically (how I populated the test db) and got the same results as
the test box.

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