extrude or planar problem

 From:  Michael Gibson
6208.5 In reply to 6208.4 
It's often times difficult for intersection mechanisms to get a clean intersection on things that are very nearly tangent with one another but not quite.

That's because things like that have a kind of "zone of intersection" where the 2 objects are within the target tolerance of each other across some extended area rather than at a sharply defined point.

- Michael