Ok, my expert friends.  Here's another one for you.  In the attached zip file, there are 2 part files and 3 pdf files.  The bottom line is that I'm trying to figure out why one surface will thicken to .05 (with verify on rebuild turned off), and the other almost identical (I realize the "almost" plays a big part here) will not (with VOR on or off).

Yesterday, I discovered that I was having inconsistant results when I rebuilt, and realized I needed to turn VOR on to ensure I was building a good model.  That resulted in the revealing of many problems.  The first one that had me stumped was posted yesterday (https://forum.solidworks.com/thread/26413?tstart=0) and while no real explanation was found for why the way I had it was causing a problem, a solution that worked was found I utilized.  Subsequently, I had many things further down the tree to clean up, some probably as a result of that change.  The problem I'm sumbitting here may or may not be related to that change.

In the pevious file (simplified & sumbitted here as "thickens inward to .05, VOR off.sldprt"), works sometimes, as long as VOR is turned off.  The attached pdf's show the different results I get.  It alternates between the totally broken result, and either the good result or the non-uniform thickness result.  I haven't found a pattern other than that every other time, it's the result with errors.

As for the newer version of the file (simplified and submitted as "does not thicken inward to .05.SLDPRT"), The surface resulting from Surface-Extend30 will not thicken inward to .05, where the previous version would - and I need it to.  I see a slight difference in minimum curvature radius, but not a lot, and they're both far less that .05.  That brings me to a question I have about the "Check Entity" command (tools, check...).  Isn't there a way to have it point to exacty where on the surface the minimum curvature is?  I'm not seeing that.

Thanks for any help.

Charley Leonard