Hi Chipp, you can often times get a clue of what is going wrong by generating intersection curves by selecting the 2 objects and doing Construct > Curve > isect.
In this case the intersection curves look like this:
Note how the intersection does not form just one cleanly defined closed loop, there are several different loops running into each other - anytime the intersection between 2 objects results in complex situations like this it can make it difficult for the booleans to clearly identify which areas of the model are supposed to be sliced up and kept or discarded.
The problem is that the 2 objects have some overlapping surface area in these spots:
When 2 objects just barely skim over some coincident surface area it can tend to make it difficult to boolean them very well, the intersection can become poorly defined and not easily separated into distinct regions.
Booleans will be more robust when the objects more distinctly push through each other rather than just barely skimming over some coincident shared surface areas. So it tends to be difficult to try to cut objects in this particular way that you are attempting here.
- Michael
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