Hi Danny, yeah I think you guys have figured it all out, here is that problem surface:
The trimming curves are totally on the outside of the underlying surface...
Because all the edges are joined to other edges, it basically still counts as a solid, although with a really bad tolerance since the gap between those edges and the surface is substantial.
The bug is in whatever made that particular surface in the first place which is a bit hard to determine now. If you happen to know which modeling step that opening appeared in (like after a boolean, after an initial extrusion, after a certain step) then that could help to narrow down which operation has the bug in it that created that bad surface.
- Michael
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