Trouble projecting feature onto cuved surface

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Hi, I have been going crazy trying to figure this one out. I have read all the posts that I could find about this and they are not working in my case. I am building a model and need to place a feature on the model to simulate the connection of 2 panels. I have read may posts about this and am having troubles.
I create a plane through 2 edges of the fileted surface, then create an offset plane from that one. I create a rectangular feature on the offset plain, then create a sketch on the original plane through the 2 edges and project the rectangular feature onto the curved surface. This all works fine. I then switch the design into patch mode, turn off the sketch on the offset plane so its not in the way, click on create patch and select the projected rectangle on the curved surface. This is where everything stops. I cannot select the rectangular feature. If I click on a line, only that line is selected and I cant select the rest of the lines that create the rectangle. I can drag over the whole rectangle and select the 4 lines, but cannot finish the patch. I am not able to select the ok to create the patch.
If I create a circle and project that onto the curved surface everything works fine. I just cannot use a rectangle for some reason.
Any Help is greatly appreciated.
Tim