Curious what other people do the solve/workaround/avoid this type of issue which working with surface geometry that is bent and folded - then when you thicken it you get goofy results - which can be cleaned up, but why do will still have to do this in 2026?  The top fold and side bent are together.

If I had the time I would created a test case and use the sheet metal method to create this end and see how to arrives at the solution.  Which I suspect might be better.  Any suggestions?