Boolean Madness

 From:  Michael Gibson
2728.3 In reply to 2728.1 
Hi Brian, I've attached an updated version of your model here ( that can now be booleaned.

The way I formed the cutters was to build these sections which were boolean unioned together:

Then I removed the flat parts to open up a hole:

Then used Construct / Blend to place a smooth blend in between the edges that were now open, to get this result:

Now that has no self-overlapping parts and can be used in a boolean.

Hope this helps,

- Michael