Attached is a sheet metal part.

This AM I changed the part from 14GA to 16GA and suddenly I was getting errors that none of the cuts cut the body. Like below. 

This was fine at 14GA thickness. This explodes not only these cuts but makes the model so that I can not do any cuts anywhere on the model. 

Originally I had the initial flange length at 155mm. If I move the closed corners below the cuts the closed corners fail because the cut ends up on the corner bend. Like this. Luckily in this particular case I had enough room in the assy to be able to increase the length of the original flange to 160mm which allows the closed corners to work and allowed me to move them to the end which allows the part to not explode like the last picture.

Is this a known issue? Are you not supposed to be able to do cuts over the closed corners? Why did it work at 14GA and not 16ga?

Thanks