We build our indexes on a remote machine (that uses a slave version of
our DB), then sftp the resulting index files to our web servers, each
of which run their own TS instance that uses cron to send a SIGHUP
that refreshes the search, similar to what it sounds like Josh is
describing.
Two weeks ago, I spent a couple days trying to update this
configuration so we could use time-based delta indexing on that remote
machine to rebuilding our indexes more frequently.  However, we ran
into a number of instances where this broke search in a variety of
interesting ways... everything from only parts of the search string
being used, to partial results being returned (ie., only items older
than 3 months).
Ultimately, we reverted back to just doing full indexes and sftping
them (as described in first paragraph).  I'm not entirely sure which
aspect of the delta process is to blame for our troubles (was it the
Sphinx merging?  The Thinking Sphinx time-stamp delta indexing?  Or
just our own code?), but we went through a lot of pain when we tried
to combine delta indexing with across multiple servers.
Seeing as how our indexing now takes almost two hours (and ideally our
main site search would be updated once/hour or more), we'll surely
have to revisit this before too much longer.  I'll post the results if/
when I manage to crack this nut.
Bill