Hi Armin,
> One more question. In case I run into another split face in
> the future, is there a way to repair that without recreating
> the part?
Often times you can do a bit of localized surgery to the shape rather than full rebuild.
For example, you can select faces, delete them, sweep in a replacement face, trim if necessary to the other existing edges, then use Join to glue it in and make a solid again.
There is a tutorial here: http://moi3d.com/forum/index.php?webtag=MOI&msg=446.17
which goes into some details on how to do some "low level" surface tweaking type stuff, like in that case it is a boolean that was done in the wrong place, and the tutorial is about how to salvage the shape by repairing localized areas of it.
> I guess I could delete that face and just fill it in with the planar command?
Yeah the things you want to repair are all planar then that is the easiest way.
- Michael
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