Hi Brian, I've attached an updated version of your model here (BrianBoolean.zip) that can now be booleaned.
The way I formed the cutters was to build these sections which were boolean unioned together:
Then I removed the flat parts to open up a hole:
Then used Construct / Blend to place a smooth blend in between the edges that were now open, to get this result:
Now that has no self-overlapping parts and can be used in a boolean.
Hope this helps,
- Michael
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