I ended up just re-doing the sphere.


I did have a hell of a time getting the lettering booleaned to the sphere.

Is there an easy way to do that?

The steps I used:
(used keyshot logo eps for lettering template)
1)project letters to sphere surface
2)get center point of each letter and the sphere
3)extrude each letter by selecting direction from sphere center to letter center
[This is where the problem comes from. The projected letters only extrude as surfaces.]
4)create new sphere slightly larger then original
5)boolean merge both spheres and letters. (I now have solid letters that follow the sphere curve)
6)draw new sphere same as original size or slightly (1/64") larger
7)boolean union each individual letter with the sphere (if I try to do all of the letters at once it either fails or has voids and will not create a solid)

This process after the projection takes several tries to get good results.