Ive been try to make these 2 circle connect with an r60 arc but i cant seem to make them join properly to be able to extrude them? its says they relations on them but the repair sketch tool says there are gaps?
I think you're actually connected. Try trimming out the inner portion of the two circles. SW wants to see a single profile.
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It works for me with a variety of extrude options. Im guessing the problem is your mirror, I used equal here. Also the sketch is not fully constrained, so that will make it harder to work out what wrong. I added a midpt rel to origin. The sketch is a mixture of open and closed, can you use trim? That would force the points to merge, or show you where the gap is?
I didn't get any error message when I closed the sketch and selected the Boss-Extrude tool, and it extruded fine after I had selected all the areas. And I agree with Rob Edwards about defining your sketch.
By the way, when you zoom way in like that it looks like there's a space, but it's a graphics issue. It really is coincident with the radius as far as the software is concerned.
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