To see the flame you would need to have the furnace out and rig up a propane supply and 12v.
More not a clue thoughts:
If there are small bits and pieces (OP mentioned seeing some) coming into the propane supply for the furnace then it could be clear at times and plogged at times. You could clear out the orifice and put it back in and more stuff get into it next time.
ISTR something about that yellow tape getting into things if not done right. Not sure if the first gas pipe into the valve has stuff in it, that the stuff would get through to the outlet pipe that has the orifice in it.
Rich or lean? What about "back pressure" like a car exhaust with the restriction removed in the furnace exhaust pipe making it work ok?