Hi David, I was able to repeat your boolean merge problem over here.
It appears to be a bug in the display mesher, your actual object seems to be fine but just the display mesh generated for it is not correct.
If you export to a mesh format, the export mesher will do a more careful job and make a good result.
The display mesher is oriented towards doing things quickly and one of its shortcuts seems to have had a bad effect in this particular case.
I'll put it on my list of things to look at in the future.
For now if you can get a proper export, just ignore that particular error.
Actually you may even find that if you save the messed up model and re-load it again the error may be gone.
Pilou, you may not have seen it because the display error will not show if you have some different settings for the display mesh angle.
- Michael
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