I unchecked the "Overrides" in the sheet metal feature, and it flattens to the full length now (68.579in)
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Thanks Todd, you pointed me to the right place and I got it to work. But... Override default parameters was unchecked in my environment. I "checked" it to make it work?!
them pesky k factors are something else when flattening a round bend. I found that if they are not set right then all kind of strange things can happen and then the shop has heck getting the right bent dimensions. try doing something that is 12ft dia and have a goof or two...that is a lot of scrap.
For any large radius bend, i.e., where the bend radius is 5x the material thickness, the neutral axis is right in the middle of the material, therefore a K-factor of .5 is correct.
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