Edge Tolerances: 0.000 to 0.008
median = 0.006 average = 0.005
… might be a problem…
if you explode and untrimall the thread - you see some crazy surfaces.
I strongly recommend to do not build helix–like surfaces - many operations a likely to fail (project, trim, boolean …) as pulling and projecting is not unique.
a good approach (at least with my experience) is to only build half of a turn and repeat / array it:
… @theoutside there was another topic, where moving the part a small steps gave a solution… cant find it at the moment.
kind regards - tom