Error in the surface of the sweep. my bet is that curve creation method is what you want to look at. Here I created it in a different way. Generate a good sweep and boolean success.



Maybe you want to discuss more "How" you created the sweep? If you focus on that part you can probably jump the hurdle.

(In the beginning of the video I zoom to the surface and show the degradation.... Just watched the video and realized it doesn't actually "show through" in the video. If you open the file and zoom to the surface, you should see it more clearly.)