Alright, I am starting to get frustrated with this project. I am trying to "wrap" the attached solid in 10 gauge sheet metal. My forming/laser guy suggested I use a .135 radius and a k factor of .35. Even after manually adding the rip sketches I cant seem to get it to work when it should. I feel I can make the whole center section one part (from the furthest rear sketch to the furthest forward sketch) then each end should also be able to be made out of one part.

I am using solidworks 2010 on windows 7.  Can someone please take a look at the attached part and help me figure out what the problem or problems are.

Thank you,

Kris