Hi steve,

> Had the same thing happen again yesterday, was working on
> the attached file, last night, after about 1 1/2 hours working
> with the same file, <...>

Hmm, yeah so loading the file now I can't seem to repeat any problem with it anymore, over here it seems to boolean union into a solid fine now.

In the screenshot you show with the sort of weird wrinkle or hole near the end of a tube - that's the kind of thing that a damaged trimming boundary looks like so at some point during your work something went wrong with one operation and produced an improper trimming boundary there.

So there's definitely a bug in something, but it's really hard for me to figure out where it might have been when I can't repeat the problem in a systematic way over here, it could have been in some previous command that you used before the boolean itself.

If you find some way that you can repeat the problem in a definite series of steps then please let me know about that because being able to repeat the problem goes a long way in helping for debugging it.

- Michael