Trim/Extend Tool is removing material and creating a long gap on the rectangular tube. How to fix this issue? Part file is attached.
Since you are asking for help on this one. I downloaded your model, the trim function you are looking at results the way it should.
You are cutting away all of the wall of the tube, hence the gap. The picture you show will not happen with the wall thickness tubing you are using.
My picture is of the profile of your tube as it is against the tube you are trimming to the edge of that tube giving you the opening you are seing.
On a side note you have multiple weldments of 2" tubing in your part. I would create your sketches and do 1 feature of the tubing to manipulate as needed. Saves on file size and this wayy all similar tubing is grouped together.
Is this the result you want?
If it is, then you need to select the Body instead of the Face as the Trimming Boundary.
No, This is what I want.
I would try sketching out the entire structure in a 3D sketch and then applying the weldment profiles, this will let you create segments and choose your order for your corners.
in this case your trim/extend is not going to give you desired results as your profiles to not match up at the correct locations
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