problem with extrusion

 From:  BurrMan
5733.8 In reply to 5733.5 
Also note that the profiles are not "flat" or planar. There are out by a very miniscule amount, which can be throwing a tolerance mechanism out of whack.

If you switch to a side plan view and drag one of the edit frames corners towards the other, you will see a "flat" snap appear. Then the file is good as-is (But surely you want to fix the little pieces also)

You may want to review how your profiles became so messed up in Z. Usually, this is a cause of using some type of "make2d" command. This type of output really needs to be looked at before continuing.