Hi,
I think Join Curves (for the sections). skin the two solids from the sections with Skin Solid. Use Subtract Solidt to subtract the solids, draw a profile in the plane you want and the Cutout Solid with this profile and vector should work.
But unfortunately this is with solid tools.
kind regards
Danny

Edited by user Saturday, January 25, 2025 3:28:08 AM(UTC)  | Reason: Not specified

Yes Danny, there are some annoying little quirks that catch me out too, and still in v14, one is the Thread tool in Powerpack always default to External and a thread pitch of 2.54 aka 0.1"
The other even if you select Internal (thread) and then go back to it after maybe making another hole, selecting another tool etc, it defaults to External again, but will remember the last used thread pitch... go figure :)

Mike

Yes, I work in metric (mm). It may indeed be a conversion error or a missing conversion somewhere in the code behind the GUI. I’ve seen this type of issue before, particularly when importing files from other programs.
My guess is that when the maximum stitching/healing gaps are larger than the smallest dimensions in the 3D model, the software attempts to stitch surfaces differently than we’d expect. For example, if the dimension between surface edges is smaller than the maximum gap setting—like the 2.54mm in this case (there were 2mm gaps between some surfaces in my drawing)—the software might find unexpected ways to stitch the surfaces together.
I haven’t tested this, but it seems logical that the maximum gap should always be at least a factor (perhaps 2 or more, depending on angles and mathematical rounding, etc.) smaller than the smallest dimension in the model to avoid these issues.
Regards,
Danny

Edited by user Monday, January 27, 2025 9:32:09 AM(UTC)  | Reason: added angles and rounding

A slight modification to your idea, Theo5715:


Mostly, as you said, create two slots.

Skin, stitch, shell.

Then, add a centerline, and on it, a perpendicular surface, thickness to desired.

Split the body, leaving the solid on a turned-off layer.

Optionally, manually or via constraints, adjust the thickness of the splitting splitting solid in case the split body material changes and has looser or tighter requirements on the gap/opening.

An alternative that I usually avoid (because of how my mind works) is solids made with draft. Then, split the draft as above.

Further, if the split is likely to not always need to be perpendicular, a beveled or draft-based splitting plate (solid) could be used for faster iterative work exploration.



( Extra:

I may be wrong, but, I imagine the gap is easier to adjust later by changing the splitter thickness than by adjusting already-tight curves that if they lose associativity will potentially break the model. I sometimes get hit with an undo breaking things, and going forward hy undoing the undo further messes up things. Hence, I have hundreds and hundreds of non-deleted work that grows from 500 kb, out to 1 mb, the as far out as 100+ kb — always some incremental name-varied fallback file available.)