My turn for a weird boolean

 From:  Michael Gibson
7210.2 In reply to 7210.1 
Hi Yenmonger, that one is pretty weird. Seems to be some difficulty in processing the vertical edge of the wedge, it would unfortunately take a lot of detailed effort to figure out exactly what is going wrong.

The pieces seem to be just a teeny tiny amount out of alignment, like on the order of 0.0000064 units away from each other. Something in the processing of this particular boolean is sensitive to that I guess though, because if I move the wedge away and then back again it seems to be ok, see attached file.

I don't see anything wrong with your geometry, it seems to be a case of edge merging getting confused with this particular case and this particular distance between the edges or something along those lines.

- Michael
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