Hi Phil, I've attached a repaired version of your object here which looks like it's all set up now.
After doing the shell I deleted the mangled surfaces you circled above and joined in an extrusion there to fix up that area, and then there was also a problem in the hole in the side which was a bit more complicated because in 2 areas the edges of the offset piece were crossing each other, that required those edges to be extracted as regular curves, trim them to make them formed properly end-to-end, then untrim and retrim the surfaces and join them back in again. Then after that I built a loft for a side wall in that area and joined it in too.
I'm not entirely sure why the offsetter is trying to extend the edges in these particular areas where there were problems, it looks like they were meeting up smoothly and so shouldn't need an extension.
It tends to be tricky to extend and intersect curves that are tangent or nearly tangent to one another because the intersection is sort of more like a "zone of overlap" rather than a crisp intersection point. So some of these mechanisms that involve extension and intersection can have difficulty when the things involved are tangent or near tangent.
- Michael
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