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I've done the expanding foam trick with great success, but only on new installs. So I'd second the suggestion that expanding foam could help, with a few caveats: --as havasu said, there is potential for permanent damage. If the foam over-expands, it push up the pan or warp it. So if you go this...

Many thanks, Diehard! This is helping me become confident enough in the design that I'll go ahead and pull the permit and get the ball rolling. I might run the actual gas pipe sizing equations on the design (rather than just using the longest length tables) just to be totally sure I'm within...

I'll need an inspection only if I run a new line to convert the range over to gas, as I plan to do. Haven't pulled a permit yet, though--wanted to make sure I know the full scope of the project before I dig in. Copper is acceptable here in MN, as long as it is Type L or K.

Thanks all! It is a natural gas system, not propane; my apologies for not specifying in the first place. Actual loads: Furnace: 100,000 btu / 91 cfh Water heater: 40,000 btu / 36 cfh (longest length, 20ft from secondary regulator) Range (proposed): 54,000 btu / 49 cfh Total: 194,000 btu...

All of the piping in the whole system is 1/2” copper, except for a very short section of 1/2” black iron where the line goes into the furnace. Using the longest length method from the second regulator, I should be good. I’ll have to find out about allowable pressure drop from our city...

I am planning to convert to a gas stovetop (from electric), and so I started reviewing my gas system to make sure my piping is adequate to add this additional appliance. I need help in figuring out the effect of a regulator on my pipe sizing. All charts that I've seen for gas pipe sizing have...