Hi Simon, it's hard to tell from a written description, can you please post the .3dm model file with the objects you are trying to boolean?
You can get that type of behavior if the objects being booleaned are not closed solids, or if they have any areas of self intersection where an edge or a surface folds back over itself.
Also Shell in MoI for thickening an open surface only works very well if the surfaces are smooth.
If you can post the file that would help to give you more specific information on what's going on in this particular case.
- Michael
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