This is so great.
After posting, I was starting to figure as much about the way that I created the booleans, so I started from scratch with clean geometry and got something much closer to what I was imagining. You are absolutely correct about the fact that my two profiles - the clean one and the one that I used to boolean - were very close to each other. I will definitely make the next one more like your sketch.
Thank you so much for the detailed explanation. Understanding the underlying structure, where the various geometries have trouble interfacing and such, is really helpful.
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