it worked sending it to PayPal, the question now is why the test setup works in one site and not the other.
Why would site 2 not be using the sandbox url when I've hard coded
$PP_DirectPayment_required[$nextIndex] = "UseSandbox";
$PP_DirectPayment_required[$nextIndex] = "true";
the only other file is require_once("WA_eCart/Adv_CO_Scripts/PP_DirectPayment_PHP.php");