Hi Jeff,
Thank you for getting back..
Yes, both of those options have always been off, or have been off for a while now.
The steps I took.
Added the PIR Sensor, moved it aprox into position.
Created a sketch around the circle of the lens, extruded a hole, centered the lens to the nose, then created a ridged joint to move the PIR Sensor into the center of the hole.
The PIR sensor did not have a joint fixing the lens to the sensor so I added one into this design so that all the parts travled together.
The to mount it, I created a sketch using the PCB of the sensor as my sketch plane, I intentionally projected the circles on the PCB as drill holes, then created a bigger hole
for the mount and extruded the post into the front of the nose.
When I looked at the extruded result, one side of the post was flat, clipped so that it had a D shape. I went back to the sketch and saw a bunch of purple.
So I removed the two vertices that were causing the clipping and it fixed itself.
I later went back to the PIR Sensor, added the joint internally to that part for the lens/sensor and rebuilt the timeline with the new part.
The problem did not happen again, but right after that I had to do some rework on the lower snout around the pivot of the jaw and saw that a bunch of geometry was projected there too.
I typically find this error after the fact, i.e. I create a sketch, create a feature, all is fine, then later I open the existing sketch and I find purple.
I think it's always when I am using another component's plane as the sketch plane for the sketch. i.e. using the PCB of the PIR Sensor as a sketch plane for mounting points, which results as a sketch / feature into a different component, in this case the HeadFront.
I don't think I was in the Project comment. I almost never invoke the command the select vertices, most times I am right clicking a highlighted sketch item and select /sketch/project. In this case the drill hole in the PCB.
Is there a hot key that auto projects underlying geometry.
The other odd thing about it, is that it always seems to be multiple copies. If I select a piece of projected geometry and right click/delete, if there are multiple copies the delete command does not appear to work because the second copy just bubbles up to the top. If I draw a selection box then select delete it will then delete all copies.
Another odd thing when I was reporting this, was when I tried to remove the geometry with a selection rectangle, it would not draw a rectangle it was this odd spline like shape. I should of taken a snapshot of it then because I haven't seen it since. Usually I will left mouse click then draw a selection area as a rectangle. That night when I tried to do that, the vertices of the selection rectangle were like splines, so it would highlight a selection area bit it would be this odd shape.
Thanks again for following up.
-John