> but maybe I shouldn't rely on booleans too much... but it's so fast and sweeeet! :)

Actually, it's fine to rely on the booleans... This really isn't a problem with the booleans, the problem is with the filleting mechanism...

Sometimes you can do a few steps to make things work better - like for instance if you're going to do a boolean with a cylinder, there is an extra "seam edge" that runs along one side of the cylinder where the surface comes to be closed. Sometimes it is possible to rotate the cylinder so that particular edge is not running right close to other things before you do the boolean, or even so that it won't be a part of the result since it will be in a trimmed away area. That makes less edges and less opportunity to run into the fillet bugs that won't cross interior edges.

- Michael