How Can I Combine Two Faces that Are Aligned on a Solid Body?

[Fab_Things]

I am trying to figure out how to eliminate the horizontal boundary line between the two highlighted faces.  This line went away on the sides when I got the faces aligned but, the highlighted one and the one on the opposite side still have this line.  I've tried zooming in to see if the faces are slightly off but when using 'measure' it never highlights a second line to select.  How can I combine two adjacent faces like the ones highlighted?  (design file attached)

[Fab_Things]

@TheCADWhisperer working on this now!  How should I add the 3mm thick additional rectangle highlighted in the pic:

[TheCADWhisperer · Accepted solution]

@Fab_Things 

Temporarily hide the visibility of the Body and the first sketch.

Start a new sketch on the XY plane.

Sketch a centerpoint rectangle to the left of the Origin as shown...

It was unclear to me if you wanted symmetrical about the top and bottom and only shifted to the side or if you also want shifted top to bottom of the rectangle relative to the rectangular hole...

Turn the visibility of the first sketch back on and mash p on the keyboard for Project (geometry) and select the four lines for the hole from Sketch1.

Hide Sketch1 and make Body1 visible.

Extrude Sketch2...

Of course we could have added this rectangle to Sketch1, but it might be best to not overcomplicate individual sketches.

[TheCADWhisperer · Accepted solution]

@Fab_Things 

Now add your Fillets (it is usually best to add Fillets late (or last) in the design as placed features on the solid body rather than in sketches).

Order of adding Fillets is critically important to the outcome...

Double click any dimension or Edit any feature to change any dimensions.

@Fab_Things 

It is late here.  I am going to bed.  I will check back in the morning to see how  you made out finishing the design.

[Fab_Things]

Hi @TheCADWhisperer, so when I create the rectangle that defines the hole ("small rectangle") in the die part, it is staying blue so I cannot get the larger sketch to extrude with a hole in it.  I tried adding  parallel constraints to the small rectangle but it errors saying the sketch is over-constrained. What am I doing wrong?  Updated file attached.

Edit:  I updated the sketch to have the same constraints you have in your screenshot but it still remains blue:

Clarification on what you mentioned above:

1. It was unclear to me if you wanted symmetrical about the top and bottom and only shifted to the side or if you also want shifted top to bottom of the rectangle relative to the rectangular hole...

==>It does need to be shifted both top to bottom, and side to side.  The arbor press I'll be using apparently was not made with everything properly aligned 😕

[TheCADWhisperer]

@Fab_Things 

You appeared to have taken wrong turn at first sentence in Message 19.

This should be a Centerpoint Rectangle at the Origin.

Also you created this third rectangle in Sketch2 where my instructions were Edit Sketch1 and add it to Sketch1.

I think you are jumping ahead and getting confused by the forth rectangle (for the offset center).

Us my step-by-step instructions to finish it my way - and then we can go back and make any edits necessary to get it exactly matching your true Design Intent (editing after the fact is trivially easy when robust modeling techniques are used).

[Fab_Things]

Hi @TheCADWhisperer, I am reviewing from message 19 onward.  The rectangle being added starting in message 19 needs to be off-center.  You mentioned in another post that I shouldn't use the move command to reposition design elements but, I cannot move them by simply setting the selection filter to whatever element (e.g. a sketch profile) I need to move and then trying to click and drag it.  How should I reposition this rectangle?  And, is the proper way to mark where I need to place this rectangle when moving it, is via construction lines?

[TheCADWhisperer]

@Fab_Things 

Do it exactly by my instructions.

Once I verify that you can follow my instructions then we will go back and edit to achieve your true Design Intent.

[Fab_Things]

Ok, sounds good! @ theCADWhisperer

[Fab_Things]

"Now sketch another 2-Point Rectangle at the Origin (be careful not to click on the construction lines of the previous rectangle..."

@TheCADWhisperer  How do I sketch a 2-point rectangle that is centered on the origin? (I know how to do one using a center rectangle but, not a 2-point one).  

[Fab_Things]

Hi @TheCADWhisperer,

Attached is the finished design following your step-by-step instructions, with the exception of Msg #19: "Now sketch another 2-Point Rectangle at the Origin"  While awaiting when you have the chance to reply to Msg #29, I used a center-point rectangle for the one in Msg #19 - it has the dotted diagonal lines like yours so I hope that is acceptable.  If not, please explain how I can center a 2-point rectangle on the origin like you did as I do not see a midpoint constraint in your file.

Thank you for steering me in the right direction!

[Fab_Things]

@TheCADWhisperer I just posted the finished file in the message above.  I accidentally replied to myself for that message 🙃. 

[TheCADWhisperer · Accepted solution]

---

@Fab_Things wrote:

Hi @TheCADWhisperer,

"Now sketch another 2-Point Rectangle at the Origin"  While awaiting when you have the chance to reply to Msg #29, I used a center-point rectangle for the one in Msg #19 - it has the dotted diagonal lines like yours so I hope that is acceptable. 

---

@Fab_Things 

Yeah, it was 1 or 2 AM here when I wrote that.

My mistake.

I'll take a look at your file now.

[TheCADWhisperer]

@Fab_Things 

Carefully examine the dimensions in the attached image (Especially the red dimensions).

Tell me what dimensions you want to change and what they should read (you might have to do some calculations considering the edges I used as datums).

[Fab_Things]

@TheCADWhisperer 

Thanks - working on this now!

[TheCADWhisperer]

@Fab_Things 

I just realized that I missed one...

[Fab_Things]

@TheCADWhisperer 

I've attached two files.  One is the notated dimensions picture - green boxes are good as is, red ones need adjustment.  There's a design element I noted in the dimensions picture and attached the referenced file in that note for you as it just contains the particular design element involved.

Edit: Referenced file deleted due to a mistake I made in it.  Will repost the corrected version Friday late morning/early afternoon PST.

[Fab_Things]

@TheCADWhisperer 

Oi, I meant to notate that in the other file!

This feature should be flush with the front of the die

so the spacing should be 0 instead of 5.

[Fab_Things]

@TheCADWhisperer 

Caught a mistake I made, will repost the notated dimensions file Friday late morning/early afternoon PST.

[Fab_Things]

Morning @TheCADWhisperer,

Attached to this message is the updated notated dimensions file.  I look forward to next steps!!

[TheCADWhisperer]

@Fab_Things 

See the Attached file...

Make Sketch1 and 2 visible.

Right click on the sketches and select Show Dimensions (if not already visible).

Be aware that it is impossible to measure beyond 3 decimal places without specifying temperature and humidity.

It is not possible to manufacture beyond 3 decimal places.

If the dimensions match your design intent - then I can create a video on exactly how I edited the dimensions.