LMAO. Calfo says his town in PA was #2 on the list of rainy cities, right behind Seattle.
I spoke on the phone with keto (thanks for the info man). He basically confirmed that it was most likely the limit switch and that the regulator on the LP was not likely to have malfunctioned. He said especially with as hard as these units have to run in a gh environment, those thin metal diaphragms weaken and react to heat much more easily. I asked him about bypassing it, but he said those switches are the only safety device these types of units have, so probably not a good idea.
When I went out to the gh tonight, outside temp was 9 F. The inside thermometer was reading right at 70 and was in the same place, on the north end away from the framing and behind the furnace where it was reading 76 last night. I got a little worried because I know that would most likely drop the tank temps some overnight. I got a flash of brilliance and loosened the screws that hold the switch into the casing of the furnace enough to create about a 1/4" air gap between the switch and the casing, hoping that maybe that would allow some air to circulate around the switch and prolong it's activation. The burner stayed lit for about 6 minutes but the thermometer hadn't moved yet. I walked to the opposite end of the gh and it was distinctly warm so I plugged the one HAF fan back in. The burner continued to stay fired and then I could sit there and literally watch the thermometer start climbing. It ran with the burner lit for about another 12 minutes and I figured it was going to stay lit, reached over to turn the thermostat down from 95 to it's normal 86 and the furnace shut off!!! The inside temp had satisfied the thermostat. I sat there and watched it run through another cycle just to make sure and it stayed lit through the whole cycle and shut off like it is supposed to. At least that blower fan is going to get a break tonight.
YIPEEEE.
It never did do any good the past few days to turn the thermostat up because no matter how high it was set, the switch was shutting down the burner before the temp could be reached.
Hopefully, now I can take the plastic off of the tanks and resume some "normal" operation.
Peace of mind is a good thing.
I am still going to check on getting those replacement parts just to have stuff on hand for any case that might come up that would be more emergent than this was. Even same day delivery would be too slow if the whole furnace stopped working.