The problem is not that a lofted bend will not flatten. It is
that the way you have created the features will not flatten. If you
create a smooth curve you will have no problems.
Yes that does work and i have done that many times but by
doing it that way the part will not look and be the way it will be
made, this part will be laser cut and formed on a brake
press
Lofted bend is a real pain sometimes. I have had to fudge
more things with this feature than anything else be far.
Unfortunately I cannot open your 08 file to help, but you will find
that you need to work around lofted bend features rather than
letting them work around what you want to do. Also, be careful with
lofted bend flat patterns, they are not always accurate.