Hi Mark, so also as a preparatory step it would be a good idea to clean up the profile curve so that it's not constructed out of a bunch of little fragmented segments.

If you select your curve and then run the Edit > Separate command on it, you'll see that it is actually made up of some small segment pieces like this (you can select them individually after separating them):




That's not so good because when you construct a surface from that by extrusion, each one of those segments will extrude into its own separate face, which means you will have some more fragmentation and more edges and faces in the result than what is really necessary - it would not be the cleanest possible model structure with the fewest number of edges and separate faces in it.

The easiest way to clean that up is to use the Rebuild command on the joined result (before separating). Some information on the Rebuild command here (you need to set up a keyboard shortcut to run it):
http://moi3d.com/2.0/docs/moi_command_reference10.htm#rebuild

In this case I'd recommend running Rebuild, set mode to "Refit", and enter in a tolerance value of 0.001, and check "Delete input objects". That will reconstruct your curves and make longer more simplified segments out of the areas that have multiple small segments in them in the original shape.

After rebuilding if you then use Edit>Separate and select the pieces you'll see that there are only 4 segments in that rebuilt result - that cleaner segmentation will then help make a cleaner output model when you construct from it as well.

So anyway, cleaning up the segmentation of that profile shape is one thing that would be helpful.

- Michael