There are some things that I want to adjust in the future which probably would have helped you out quite a bit in this case.

I'll probably do the equivalent of Rebuild automatically on the curves generated from intersections, projections, and offsets, and also probably try to adjust how sweep generates its output surfaces, trying to make some longer surfaces in cases like this instead of necessarily making one individual surface per segment (although sometimes that can be useful to be able to separate something that is more like a pipe with joints so it is a somewhat tricky area to mess with).

- Michael