Unable to Keep Spline Curve Straight Between Sletches

[MaxHugen]

Apologies for being long-winded, struggled to explain this in simpler terms.

Designing a wingsail for an F50 catamaran in the SailGP. It consists of a wing and a flap, each in 4 segments. Created the wing and flap profiles in the initial XY plane, then created 4 construction planes with new sketches, and copied the objects to each sketch. These were appropriately resized, positioned, and angled at 4°.

Each individual flap segment can be "twisted".  That is, the flap profile in one sketch is at a different angle to the one above/below it.  Aerodynamically, this allows the complete wingsail to have a different Camber and Angle of Attack, from bottom to top.

The following image shows how one of the sketches is "tilted", and how the flap alone is rotated around an axis. I've also added a Screencast below, on how I'm doing this.

The Lofting for the lower 2 flap segments is simple, as the Trailing Edges on these are straight. However the top 2 segments have curved Trailing Edges, so spline curves were used to join the top and bottom profiles, and used as a Rail during Lofting.

The issue I'm faced with is that this spline curve should appear curved in the Front view which it correctly does, but straight in the Top view - which it doesn't:

What's more, it appears as though the the profile on sketch "Profile Plane2" has somehow been "split" by the Lofting:

And I got Loft warnings:

As a novice I've already learned quite a lot, but I'm getting out of my depth here, and can't find anything on the Internet/YouTube to help me resolve this.

Any advice would be really welcome!

[barry9UDQ6]

Shell should do it https://www.youtube.com/watch?v=fs8GCX_wf0A 

Although it tends to struggle with more complex geometry, then you need to first create a copy of your outside surface using surface offset to 0, and then thicken.

Let me take a quick look at your model.

[barry9UDQ6]

Max, I have taken a quick look at your model.

None of your sketches have any constraints, and yet they appear to be symmetrical around the CL, so I am guessing you have imported them. Although there are a couple of minor problems, this is your aft most sketch, where I have drawn the CL in white:

As you mentioned, you had some 'challenges' lofting the hull..

So while technically you have succeeded in creating 1 solid body for the hull, because of the manner in which you created it, trying to do anything with the geometry may very well be impossible.

I am unable to use shell, or offset surface etc. my computer (which is a good one!) just locks up.

If it is possible to create internal voids etc. as you want to it is going to be a very difficult operation where you fight against yourself every step of the way.

[MaxHugen]

Thanks Barry, that video on creating a shell looks like it will do the job.

I created each sketch in F360, doing one half of the profile, then using "Mirror" to create the full profile and ensuring it was symmetrical.  I'm surprised that you say there are no constraints.   After mirroring, I used the Coincident constraint at the top and bottom points of the curves to ensure they formed a closed profile, and were correctly on the centre line.  I also used the Horizontal constraint on a number of points.

I'll check the aft section - this was the first one I did, and I may have overlooked the two Coincident constraints that it should have.

The F50s have to fit into standard 40' containers, as the SailGP races at venues around the world. The hull is 15m long (~49'), so the bow section is separate, and gets bolted to the main hull during assembly.

I'm a bit confused - do I have a solid body, or a surface body?  My intention was to create a solid body, then "cut" it into two separate bodies.  This would also give me a flat section on each body from which I can use the "thickness" tool.  Does this sound feasible?

[MaxHugen]

I checked the aft most sketch "Section Transom", and it seems to show the Coincident constraint?