Although, i think my post was kindof misleading with the way i described it...

Michael DID give a description of what was causing the issue. It's NOT the seam edge.

I could "pole" the group to discover my mistake.

You could also rotate the spheres seam further into the base object and get good results too, so it's not really the "seam"...

But since we are making an avoidance move, i chose seam out, to get rid of the pesky rascal anyway....

Note to self.....

The more funny is that my solution of the Boolean Merge resolves all but you must make some manual clicks! :)
(2 in this special case)

That seems to indicate the code to pole what part to throw away, is where the issue lay...

(See what i did there!)

@BurrMan:

It's hard to explain puns to kleptomaniacs because they always take things literally.

¡¡ To be clear, I am NOT suggesting that anyone is a kleptomaniac !! (…its just a pun)

Lol, Mindset....

I DO want to have a good time and be light with everybody... but i also forget that i am in a multi national setting, and i don't always get my point across....

And google ruins it, because they have a thing called "translate", which is NOT a translator, but a simple and often incorrect word exchanger...

But i'v learned to live with it.... it causes me to Take things, literally!