The attached part is a copy of one that has many more features, but I deleted everything after the first failing feature for file size and simplicity of the discussion.  With this part, I get completely different results with the "verification on rebuild" option checked, as opposed to when it's not checked (fewer errors, but inconsistent, alternating results).  Can someone opent his up and tell me what the problem is with fillet 6 that causes it to fail when "verification on rebuild" is turned on?

Thanks