struggling with Thicken command

[aono.alexandre]

Hello all,

I'm trying to copy a panel from my car to 3d print it, but the part is very annoying as there is very few references (like the planes are not parallel, or the shapes don't align etc...)

So my approach to tackle this was to create the two upper and bottom "brackets" then 3d sketch the in between...

My workflow is a bit messy, but long story short I've managed to print a sample and test fitted to the car... of course it didn't work first time, and I had to do some changes....

There comes the problem, once I've edited the 3d sketches I used for creating the surface lofts, the thicken bodies didn't recompute and didn't create the geometry....

I've changed few things around and eventually managed to thicken some faces individually but this happens everytime I edit the lofts....

Is there any way I can see where the thicken command is failing and try to address only the areas affected instead of gambling and moving this around?

Apologies, this is my first post here not sure if I shared the right file for help....

[TrippyLighting]

Trying to loft from a fillet into a sharp edge almost never results in geometry that can be thickened:

The way you create these lofts, there is a near tangency condition across the seam. It might start tangent at the fillet, but then as it approaches the sharp edge, tangency is lost:

There is no bug in the software here, your workflow, on the other hand,  has some potential for improvement!

[TrippyLighting]

My recommendation for modeling this would be to model this as a sharp edge, thicken and then apply a variable radius fillet to the inside and outside after it's been thickened. 

[aono.alexandre]

Thanks for the suggestion, but it didn't quite work (although it makes it easier to draft my rail lines....)

Interestingly the face that seem to struggle the most to thicken is the one adjacent to this one you highlighted....