Hi Leonard, check out the attached model - it should now boolean for you properly and give you a clean cut.

I scaled it up by 10 times in size - you can scale it down again if you need to have the final model smaller, but really the key thing is that when I created the sweep I made sure it did not run over top of itself and had some clearance here:



- Michael

Hi Leonard,

> When I created the thread profile I made it so the legs
> extended half way between the helix cycle so there would
> not be a gap.

That could be good if it was like 2 separate objects that were meeting up and then would be joined together.

But having a closed object kind of skim along its own self like that creates ambiguity in the intersection calculations.

- Michael

I enlarged everything 10X and adjusted the profile and presto!

Edit: Added pic of the clock. You can see the two screws on the front. The width is 8"+.

Thanks for the help, Michael.

L.