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Been having this issue, trying to make an instersection with two semicircles and I'm using the mirror modifier to do so. However, when I do that, the best result I get gives me these huge holes. Am I missing something here? How do I fix this so that they are perfectly aligned and do not clip into each other?

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    $\begingroup$ Can u provide blend file? $\endgroup$
    – Chris
    Aug 24, 2022 at 16:57

2 Answers 2

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If I understand correctly what you're trying to do, create yout half cylinder, then an empty. Give your cylinder a Mirror modifier, enable the X and Y Bisect option, choose the empty as Mirror Object:

enter image description here

Now rotate the cylinder 45° on Z, you have your intersection:

enter image description here

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Take a cube rotated at a 45 degree angle and use a Boolean Modifier to create a cutout of your tunnel with the perfect shape.

enter image description here

enter image description here

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Edit: I just noticed this, in these images my object is actually rotated a bit in Object mode, which is why I have to mirror along the Y and Z axes instead of X and Y

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