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I brought the file over from Solidworks as a step file... prt>>step. Therefore, question one would be, is something wrong with the way Solidworks is doing the conversion. Note, I have tried IGES but Fusion barfs on it.

 

Regarding the gouging, I guess I could select the axis carefully for setup 1 and then clean the slot up in 2D. I might have to hand code some G1 A'whatever" after the tool goes to home after op2.

I'm going to leave this open until I resolve the file issues.

Thank you!