Skeletal Modelling, Laser Cut Joints

[learn001]

Ok, So I've been trying to look at skeletal modelling techniques, and have managed to make the following box for my enigma machine (http://puu.sh/26mzs)

From my skeletal model (http://puu.sh/26mrT)

A part example(http://puu.sh/26msY)

My workflow for this so far, has been,

1. create skeleton surface's from sketches,
2. derive a part from each of the surfaces,
3. link the parameters for each part to a part file, whose sole purpose is to provide parameters (to avoid circular linking by linking to the assembly)
4. click the derived surface face,
5. thicken the plate,
6. exit editing the part.
7. ground the part in the box subassembly.

 All the parts are currently interfering, as so far, this is feeling good. but what would the best way to approach adding in these laser cut joins be?

Additionally some feedback on my method used would be great.

[learn001]

Havn't tested this yet, But have started mocking up each join as a 4 solid part, 1 for each positive, and 1 for each negative.

The idea, is that I can constrain the joins in the assembly as a part, then tell each derived part, to combine, and cut the joins.

I don't quite understand how to make them adaptive however, so that the  tab lengths can differ.. any help on this?

[learn001]

As I feared, I Can't work out how to ACTUALLY use these parts to remove material from the box parts..

[johnnr]

1. Length

In the join part, goto manage tab,create ipart

2. Cut

Locate the join at the right position in the box in assembly, then derived new box part with the joint been cut

[learn001]

I don't understand.

when I try to derive part, it just places it randomly, and I can't find a way to select the instance of the part that I want as it claims I'm making a cyclic link.

[learn001]

Maybe this isn't the best approach, it seems like if i could get it to work it would be ideal, but I've seen people talking about ifeatures, those seem that they could do the job easy enough, but is it possible to link 2 ifeatures on 2 different parts, so that the design intent is maintained?