Hi Billabong,

It sounds like most of the problems are related to using MoI as a surface modeller rather than a solid modeller. In other words, trying to make a bunch of individual surfaces and stitch them together rather than making simple solids and using those as components or cutters.

Surface modelling is tricky, but Kuechmeister Swagger is really good at it and so makes it look easy. Like how professional athletes make scoring goals look easy.

For organic shapes that require surfacing there are some more tutorials here:

http://www.k4icy.com/tutorials.html

However, maybe starting over and sticking with solids for a while would help. Looking at your model it seems like much of it could be made by adding and subtracting simple solids and then filleting to blend them together.

- Peer