Good evening Solidworks aficionados.

I've run into a peculiar problem attempting to perform an extruded cut on a lofted boss-base part. I'm trying to do an extruded cut from face using a closed sketch that uses curved converted from the loft. This results in a Zero Thickness rebuild error. You can see what I'm trying to do in faceExtrudedCut.jpg and the sketch with its referenced curves in sketch.jpg. While experimenting, I discovered that cutting through all will leave a razor thin surface running around the outer curve (see extrudeThroughAll.JPG) Despite the curve being supposedly identical to that of the sketch.

I've rebuilt the loft and sketches numerous times, sometimes running into similar errors on the other cut parts, sometimes not, with little apparent rhyme or reason.

After a lot of experimentation and a lot of digging on the internet I'm kind of out of ideas. If you could offer a solution or a better way to acheve what I'm going for I'd be most grateful.

I've attached the part to this post.

Cheers.