Hi SurlyBird, thanks for posting the pictures, those help a lot.
So one thing that can be good is to imagine how that part is actually physically manufactured.
It's not going to be built in little pieces welded together which is basically how you're approaching it in MoI - instead it is going to start with a piece of stock and then have pieces removed by drilling and cutting. Try going through more of a similar process, but you can use a lot more custom cutting heads than what an actual machine shop uses.
So like that scalloped area would probably be easiest as one long sweep that just continues to extend outside of the object instead of worrying about building pieces that are flush to one another all the time.
I'll try to make some steps to illustrate.
- Michael
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