Sketch object projected from a part surface not closed

[mad.macs]

I have a body that was imported from a .3DM file. I took the body and split it in half. I created a new sketch on the split surface, then projected the face. The result is an outline of the objects face, but it isn't complete, There are tiny gaps in the resulting outline. The outline does not fill in blue like a closed path does, and I can't extrude the sketch. Whats weird is I can do an extrusion of the face so Fusion recognizes the face as a closed path. If I do extrude the face, I still can't use it to project a closed path.

Split body Projected face.

Result of projected face, Interior is closed path exterior is open

Open path in sketch. Opening so small. Fusion freaks out and slows to a crawl when I zoom in to fix it.

[jhackney1972]

Can you please share the model.  

[mad.macs]

I had to modify it, I tested it again and the projection still fails.

[jhackney1972]

I do not know what to tell you.  I created a new component from the face extrusion, which you said works, and save it out as a new model.  Then opened it up and it does the same thing, will not project correctly.  Mainly one point that you pointed out earlier.  @jeff_strater what do you think about this?  I marked the point that always fails.

[mad.macs]

I can't get it to create a closed path from the extruded face either.

There is another version of this part that had like 6 failures in it. 

[mad.macs]

This part has more failures.

I should note that these are files we are receiving from a client, and this is exactly what we need to do with their files. I'm going to see if we can get them in IGES or STEP, and see if there is any improvement, but for now, this is what I have to work with.