Hi Gord, so is that going to work ok for you? Are there other problems to fix still?

So I think one problematic thing in your original one is the alignment between these pieces here:



The one on the left looks like it's trimmed off from a horizontal line:



Then the one on the right is the natural end of a Network surface:



The problem is that even if this edge:



And this edge:



Are both on the same plane that isn't going to be enough for them to get glued together well. The edge on the left coming from a trim that is interior to the surface while the one on the right coming from a curve used in Network is not going to guarantee that the shapes are going to be close enough together.

It's good for these juncture areas to be formed either by being constructed off of the same end curves, or by being intersected with each other. One coming from a trim and the other from a separate curve is not going to be good.

So if you then build separate block chunks out of these things and then try to boolean them together it's going to be something similar to this (shown exaggerated here):


And if they are pretty close to the same shape but not close enough to actually merge together, those little "shelf" pieces above are going to be really skinny slivery things which you don't want to have.

That's one of the ways things can actually get worse when things are really pretty close to matching up but just not quite enough.

The other possibility to get things like this glued together that are not quite aligned is instead of making 2 blocks right up next to each other you could leave some empty space between them and put in a transition surface like a Loft or blend between them.

- Michael