Hi Billabong,
Luckily MoI can do both surfaces and solids in the same environment and has operations that blend the two like using a surface as a boolean cutter for a solid.
Several of the problems that have come up sound like they stem from using Network when it's not the best tool for the job. Like when Michael said above that "That looks like it wants to be an extrusion that is trimmed but instead it's something that's surfaced directly between 2 long curves..." or also the nearly-planar surface that he pointed out.
So, instead of surfacing everything you could use solid operations for most things, and only surface when it's required. For the model you've been posting most if it could be done with solid operations from primitive solids like cylinder, sphere, revolve, or extrusion. For airplanes and cars there's lots of surfacing. But even when doing surfacing life can still be made easier by putting together solid "components" from the surfaces and then booleaning those together.
I understand you're already doing that, but the simpler each component is, the easier it will be to troubleshoot rather than looking for a needle in a haystack when trying to put a bunch of surfaces together at the same time.
For micro edges there's a plugin tool for finding them:
http://moi3d.com/forum/index.php?webtag=MOI&msg=11271.13
The problem with surfacing is really that NURBS is a system capable of extreme accuracy. That sounds good, but it also means that it's intolerant of the slightest inaccuracy.
If you make solids that push through each other a little bit (overlap in 3D space) and then boolean them the overlap gives some slack to the boolean algorithms when figuring out how to combine the shapes.
Even when surfacing, it's best to use large surfaces that intersect so that the intersection can be used as the trim / edge. That get's rid of the accuracy problem by guaranteeing that the 2 surfaces meet along a common curve.
But, if you are going to build things up from surface patches you will need to work to the same in-human level of accuracy that NURBS entails. Like in your video, you move around some curve endpoints to get them to match up. That doesn't mean that the curves match up with the rest of the 3D object. And those tiny imperfections that are small on a human scale are actually large on a NURBS scale, so the software has no choice but to decide that the surface patches are too far apart to join.
- Peer