Hi Michael,
I am only horning in on this discussion because I am having this same problem. I have a complex file that originally suffered badly from the duplicated surface problem, with 1928 surfaces, and I have gone through and removed all the duplicated surfaces using v3 beta and, I thought, closed open joins. I have spent many many hours working to get it to a solid, but can't seem to get it to work. I am up against another deadline, so would appreciate you taking a look at it. May I send it along?

Best regards,
Bill Parker

Hi Bill yup go ahead and send it over to me at moi@moi3d.com - if it's particularly large you may need to use a file upload service like https://skydrive.live.com/ or dropbox and send the download link to me instead of sending a particularly large file as a file attachment only, if it's above 10megs or so it probably won't come through as an attachment.

- Michael

Thanks Michael, it is loaded to SkyDrive, you should be getting an email.