Hi, I am trying to use the boundary boss/base feature to model a weld-like feature (it has to be modeled in this way to ensure a good throat thickness). I have modeled several similar joints without problems but for some reason for this specific joint I cannot get the boundary boss/base feature to merge with the rest of the bodies. 

I am using the exact same technique that I've been using for all my other joints. Does anyone see where the problem is and how I might be able to solve this?

I have attached the .SLDPRT file in question. The last feature is the boundary boss/base where I have unchecked the 'merge result' box, but it should merge obviously. Whenever it just shows 'Failed to merge the newly generated body with the workpiece'. Any ideas?

Thank you,

Kris