Hello all, I am fairly new to SolidWorks so please bear with me.

My example part is a square to round transition that is constructed from a single piece of sheet metal, the problem arises when I try to create a lap for this part. I keep getting the Tab feature is crossing a bend error even though I used the jog command to ensure the lap doesn't interfere with the part. I have tried to change the jog radius, offset and position as well as making the cut that opens the profile wider but it still fails from the same error.

I created the sheet metal profile using the lofted bend command, then I cut the profile in half, then I added the Lap and Jog...  I'm not sure if this is correct way to go about this, but when I suppress the the cut feature the tab and jog features fail. There seems to be no information in the help section to describe whats going on and I'm not having any luck with google either.

If someone could kindly point me in the right direction or perhaps provide an example I would greatly appreciate it, I have attached the file and it is drawn in SW 2014 SP4.

Thank You,

Chris