On Surface Density-Can it be avoided here?

Without seeing an uploaded sample or something, it’s hard to speculate, but there’s definitely nothing wrong with rebuilding the surface to something that is still within tolerance.

‘Rebuilding’ is a common part of most of my workflows. I usually prefer homogeneous isocurve density, but it all depends on what’s necessary for the job at the time.

Sometimes fitting a surface really tight is inevitable if you want the single surface to conform to other adjacent geometry.

For example: (sweep 2 rail) Modeling Problem/question - #16 by lander

But depending on the ‘rules’ those situations are also capable of being mitigated with further design revisions – if necessary.