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I have a half-cylinder that has been scaled in edit mode three times on the Y axis. It has a Solidify modifier with its thickness set to .7870 (arbitrary, but it shows my problem nicely). Even with Even Thickness enabled, the Solidify modifier does not handle the top of the cylinder very well:

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When I try to cut a hole in the solidified cylinder with a cube and a Boolean modifier, depending on where I place the cube, sometimes all the geometry of the cylinder disappears (I didn't hide the cube here; there's really nothing left of the cylinder.),

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sometimes it acts like I used Union instead of Difference (and it inverts part of the normals...),

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and sometimes it even cuts a hole kind of like I wanted, although it still does a very poor job.

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Inspecting the inside of the cylinder, I can see that the geometry of the cylinder is intersecting itself, and that is what I don't know how to fix. Here's my .blend file.

Edit: here's a screenshot of the actual model (side view):

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That intersection is indeed the issue.

There isn't much way to fix this without doing it manually, but the clamp option can help at least clear things up a bit:

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  • $\begingroup$ Ow. "Doing it manually" is not what I wanted to hear; my actual application has five bevel modifiers, and I want to be able to make little adjustments to them without redoing the whole thing... I might just try solidifying the half-cylinder before booleaning it. Any other ideas? $\endgroup$ – catlover2 Jul 2 '14 at 6:58
  • $\begingroup$ @catlover2 Do you think you might be able to provide a screenshot of your actual application? I'm not quite sure what you mean.. $\endgroup$ – gandalf3 Jul 2 '14 at 7:00
  • $\begingroup$ See the screenshot I added. $\endgroup$ – catlover2 Jul 2 '14 at 7:09

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