So here we are again. If I create a swept solid using a path with a "break" in it, I can later convert to sheet metal by inserting a bend selecting an edge of the cone.

However in my real world case I created the swept solid without a break in the path.

Then I later try to created an extruded cut through the cone and try the same insert bend technique. Does not work!

Am I doing the extruded cut wrong? I have attached the model (SW2011).

Thanks for your assistance.