turns out is was the thermocoupler in the furnace. Had a 'dead spot'. Worked sometimes, not others.
I got a great tip to basically arc the current inside the thermostat, using a pair of pliers to touch the two leads. That bypasses the brains of the thermostat and just flips the switch.
If it works, the thermostat is dead. If not, the furnace is not firing.
Turned out to be correct for me, so I thought I'd pass it along.
Oh, and a chilly saturday service call for a $20 part and 4 mins of time costs $285. Beat's freezing.
Thanks all for the help.
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