Hi Otterman - re: weird boolean - I have made a small adjustment to the tolerances used in booleans which makes this particular example work now in the next v2 beta.
But I'm sure there will still be other similar issues with edges that skim along surfaces, it depends on how close they are to the surface and stuff like that. So it will still be a good idea to set things up more so an object punches all the way through another one rather than just skims along its surface, if it is easy to do so. That tends to avoid the whole area of calculation that is difficult.
Also I think I'll go ahead and set up the booleans with the relative tolerance mechanism now as well.
- Michael
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