The curved surface of the body was causing errors when mating with the flag so I make boss extrude 2 for the fag to mate with. The problem is the hole is at an angle relative to boss extrude 2 so the flag won't snap in place. How do I get it at the right angle?
I must have forgotten to save before uploading. Try this one.
What you are thinking was the problem (moving flag causing errors in your assembly) is not the problem. So what you are doing here is attempting to fix a problem that isn't the problem, thus getting into other problems.
That could be a problem!
What is the material of this part and how will it be manufactured?
Because adding that little boss just severely limited your options. Unless you want this mailbox to cost it's weight in gold....or platinum.
(edit: unless you are 3D printing it I suppose)
These are things that you are going to want to think about....as they are the difference between a modeler (CAD guy) and a designer.
My advice would be to separate the top (curved) portion of the mailbox from the bottom (flat) portion of the mailbox, then attached them somehow (welding, rivets, screws...etc).
Then punch a hole in the side of the rounded portion of the mailbox and add a round boss onto your flag to go through the hole.
(edit: or a hole in both of them and add a pivot pin)
It will be made of fiberglass
Change the "on plane" relation in 3DSketch3 from the curved surface to plane1. This will make the hole normal to your boss.
I decided to just make the boss, then make the hole. That works for me.
What if you create the Hole feature after Boss2 and based on the face of Boss2?
Oops, never mind - you have curved face. Back in a moment with solution.
Hey wait a minute - there is no Boss2 in the file that you attached????