Sheet metal surface trim for plasma cutting

I have a very common situation for me that I am wondering if others have encountered and maybe I am missing something. 

I have some sheet metal fames which intersect a curved body at varying angles. I then copy the surface of the curved body and use that surface to cut the sheet metal. What I end up with is essentially what I want however the cut edges of the sheet metal are all cut on angles following the surface. These sheet metal parts then get cut out on our plasma table and therefor I need the edges normalized before flat pattern as depending on which side I select on the flattened part it changes the size of the DXF pattern.  In some cases the angled sides actually oppose each other so neither side of the flat pattern is actually accurate. I have found that the Normal Cut feature doesn't work at all for these parts. The only part I have successfully gotten the normal cut command to work was a part with no bends.