That area is in fact not undergoing any trauma, was always like that from the start.
Yes the area circled by you in red differs, and I knew it would end up spoted, and after one week of taking loads of .001 accuracy measurements and trying to recreate it all, its not worth anymore effort fathoming out that small area, both levels are circles at ends, the gap between them at top is accurate, somehow their milled and my cad see a different area, and I have measured thrice !,
I am leaning over the item with my back aching badly, I have 5 fractured vertebrae, and there is a limit to what I must put myself through, if this one area of a few .001 inches wipes out another week, it will be my undoing, so that red circled area whilst gnawing at my perfection brain must be as it comes out in CAD and we must fillet and cobweb MY CAD… forget the original image from now on. It was to show the cobweb areas effect only.
we must not get hung up on comparing them. 5 weeks when 1 was charged for.
all the very accurate dims I made should have all matched, but theirs is done in an era of no CAD, and what a milling machine does at the time can wander it seems when in a human hand.
lets just focus on my CAD and the ledges and cliffs that need 'landslips. or cobwebs !
We now have one cobweb you did using sweep2.
even the long bar in purple should in fact have its base filleted with a smal radi, perhaps 0.02 or 0.01, so that it looks the part.
This is for visual effect, its a non functioning 3D printed insertion into a larger item.
So put to one side that photo as such. My fillets or webs go from edge to edge as per Pshop doodles.
I just need to know how to do the filets and cobwebs and how to tidy up the boolean.
I had to make it in layers, nightmare to get to see best way, and the layers of solids formed with cutting shapes was the key into getting it this far.
I presume the boolean union was the correct thing to do, then MergaeAllFaces then explode it and tidy up.
To see how its done is good for me and others.
To have a Rhino file exported as V5 I can study is good.
any video making of methods is VERY GOOD.
Now to fillets and cobwebs, cobwebs with a curve type face.