Hi Gord, I've attached a version here that has been tuned up to be a solid now. I did that by identifying the problem spots using the select naked edges and MarkCurveStart scripts as mentioned above. There were a couple areas where a hole just needed to be filled in using either Network or Loft, but there were also some spots where an edge had gotten compressed down to a single point and those are more difficult to deal with. It's a pretty tricky process that involves untrimming surfaces around problem areas and then retrimming them. There is an object repair tutorial here if you want some more details:
http://moi3d.com/forum/index.php?webtag=MOI&msg=446.17

3DM file is attached. I think you should be ok to do booleans on it now:




You may run into some problems if the boolean tries to cut through an area that has some of the tiny slivery pieces, like probably a cut that has to make an intersection through this area may be difficult to do:



Hope this helps though!

- Michael