Hi everyone,

Longtime lurker, first time poster   I have done a number of sheetmetal parts in the past, but I am no expert and have had this recurring problem. What is shown is a sheetmetal box consisting of a base flange and a few edge flanges.  The problem is that the inside of the small flange(s) shown in the attached part and images below, interfere with the other edge flange(s). 

My questions are:

1) Is there some checkbox to tick, offset to set, or minor deity to pay supplicants to clear this intersection up?  My brute force solution now is to chamfer or cut the offending edge.

2)  Is there a better, slicker to close up this box?  I can't alter the inside dimensions but I can do whatever I like on the outside.

I am sure I am not the first person to encounter this but my forum search came up empty handed.  If I missed somethign though, please direct me to the post.

Thanks in advance for your help!