I have now added a quality check upon import and I get a message "could not import object". The part view that you have with all the seperated base parts never gets shown for me either. I can extrude on the side of the part with the circular feature, but i can't extrude on the side with the retangular feature in the lower section.
I opened the part with 2009 SR SP2 Build:550, copied the base to CE, unstitched, and did a quality check without any errors.
And I could do both adding or substracting extrusion on the face shown at the picture.
Can you zip and attach the original file here - I would like to use this one as a Repair lesson in my class today.
Meantime - I see that document I linked earlier is no longer avialable - try this http://home.pct.edu/~jmather/AU2008/ML205-1P%20Mat
Also - I should point out that that list of issues Inventor returned was on the part as a single part rather than as multi-body solids that it really is. When I unstitched Quality Check did not return any issues. Of course it doesn't run quality check on stuff that isn't (but should be) there - the missing surfaces.
Inventor 2010 has introduced multibody parts; it's easier then.
But if you want a cutting extrusion, just extend the short sides of the sketch over the part's contour. After that it's extruding in 2009, too.
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