Fixed, thank you.
I removed my router again and configured my Pfsense WAN to DHCP like before. Then I tried to ping 8.8.8.8 from Pfsense and received route unreachable. So I looked to verify the gateway address assigned by DUCP and saw it the entry but it was not the default IPv4 gateway. I changed that and bingo, everything is working.
I still don't know why on my test box it worked for the LAN address of 192.168.1.XXX but not 192.168.10.XXX, but since it is working on my prod Pfsense box I'm not going to complain.
Again thank you for the clue which got me looking at the default gateway setting.