Thanks to the community here for helping solve my issue with custom zone/copper pour lines: Offset line border / copper ground pour possible? - #18 by cornell
In summary, I am looking for a way (such as a custom rule) to ignore vias when working with zones and clearances.
Following up on that project with a separate issue, I would like to add vias inside these zones while keeping the historical design of these boards as mentioned in the above post. Everything works as expected before I add the Vias. What I did was create a copper pour zone the exact dimensions around each pad that would permit a ground line of a specified size.
Currently I have the zone set a minimum clearance from traces and that was the trick for the ground border lines that updated automatically to move out of the way of traces.
Since the via hole size is set to the trace diameter and the via diameter is set to double the hole size, the zone is broken around each via when I press b to refresh the zone pour, since the outside of the via diameter would make a zone area with less than the minimum clearance I set. All of this is correct and as expected with the clearance rule I set.
Due to the historical design I am not looking to expand the width of the zone so that it is not broken.
Of course I could just move away each via, refresh the zone, and then move the vias back in place without refreshing afterwards (or use a half size via), but I am hoping for a more automated way. I could not understand the documentation on custom rules and thought that may be the way to go: PCB Editor | 9.0 | English | Documentation | KiCad
The first image shows before the refresh, the second shows after the refresh, and the third shows the zone settings.