Hi jki, I investigated your model some more by using Edit > Separate on it and moving faces away one by one to look for any weird things and I did run into some little slivery degenerate looking faces here so far:
I think that some stuff similar to these is what's messing up your booleans, but not these specific ones since I removed them and still ran into the same problem. But probably there's more like these.
- Michael
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