Hi Burr,

> I'll make a short video to show some of my process and be
> clear.. There may be a couple areas to comment on with regard
> to my method.

Do you mean you're worried about your current process for rotating and positioning the blocks after the boolean is done?

Object snaps on to the corners of the box using the Move command should be highly accurate for the positioning part, and it should be fine to just use the rotation edit handle to flip the one piece by 180 degrees in the Front view.

- Michael