Ok... So some steps may be "model basic shape at actual size, scale up to make trims and blends. Possibly throw in a shrinkTrimmedSrf as well (or possibly A Seprate-ShrinkTrimmedSrf-Join)....

If much after that, it may be just an anomoly with multiple iterations of this particular model, as I havnt seen this before and I use that command all the time. Just wanted to be sure that this wasnt the expected result at this time... Thanks.