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@j.palmeL29YX @Alfred.NESWADBA @leeminardi , I see your points. I suppose the point is that you really need to use Autocad's built in snapping tools. I like to do the geometry on the side and determine things and then make the moves, but this evidently leads to undesirable outcomes due to rounding. I definitely agree that I only need 3, at most 4 decimal points—no CNC'ing to 1 millionth of an inch, but in my case the difficulty is that those tiny errors cause failures in tools such as union.
Anyway, the take away is try to do everything with a pre-defined tool and limit hand calculations on displacements, rotations, etc. I have also noticed that things are better when done in 2D first and extruded into 3D. I was trying to do everything in 3D from the start, making some things impossible that were trivial when started in 2D, e.g. rounding the corner of the L-shaped boxes.
Thank you for the quick and clarifying comments—excellent community here! Week 4 of CADing for me here, frustrating but getting better.