Hi Prop,
Yes I saww the problem you just described...Here is a file with the sweep as i think you wanted it..
I'm not exactly sure about one of the issues, and will wait for Michael to chime in.
First, the scale of the model may have been presenting issues for the tolerances in the file.. FOr instance, that little arc on top is something like .0067 in diameter..
I scaled your model up by 100 times, then tried the sweep. I still had an issue in that little top arc area with a malformed surface creation.. So I ran seperate on the 2 original profiles and seperated out that little arc on both ends (Perhaps they were joined with the small values and didnt get a good join in???) Then I used the 3 point arc command and recreated those 2 end arcs and deleted the old ones. Then I joined the whole lot and did the sweep as described before...
Then I scaled it by .01 and will attach it here.
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