Weird I tried that and still doesn't work. As far as I can tell from the template code it's checking to see if I have a an attachment thumbnail? But why wouldn't it show on every page instead of seemingly at random. I can't see anywhere in my posts where I told it to attach thumbnail to particular post. All I did was 'set as feature image'
// Check if this is a post or page, if it has a thumbnail, and if it's a big one
if ( is_singular() &&
has_post_thumbnail( $post->ID ) &&
( /* $src, $width, $height */ $image = wp_get_attachment_image_src( get_post_thumbnail_id( $post->ID ), 'post-thumbnail' ) ) &&
$image >= HEADER_IMAGE_WIDTH ) :
// Houston, we have a new header image!
echo get_the_post_thumbnail( $post->ID, 'post-thumbnail' );
else : ?>
<img src="<?php header_image(); ?>" width="<?php echo HEADER_IMAGE_WIDTH; ?>" height="<?php echo HEADER_IMAGE_HEIGHT; ?>" alt="" />
<?php endif; ?>
</div><!-- #branding -->