How to reduce corner offset when extrusion is outside offset plane

[ptr727]

I am creating a corner connector push over cap to connect extrude aluminum at a 90deg angle.

I have a model that works, but I'd like to refine the corner such that the aluminum edge touch each other when inserted.

I use a 45deg construction plane (idea from this forum, thank you) and extrude to the plane, when I try to move the offset closer to the corner I get an error that the extrusion is outside the plane.

I'm asking for ideas on how to fix this, without a brute force extrude and cut on inside corners?

Thank you

[davebYYPCU]

I figured it out.

Can I presume Top Channel and Bottom Channel are the extrusions?

Edit the 3rd extrusion to be 14" total length. Add the 4th extrusion to that.  Use the inside corner edge for the Mitre Plane position.  Extrude 8 goes out past all of the Mitre Plane, then Split Body with the Mitre Plane, and remove the offcut before the mirror.

Sorry about my early confusion if you saw that.

[ptr727]

Thank you, I got close, but not 100% sure about instructions for 14mm extrusions as it was a -2 and 10 two ways, and the plane corner selection.

I think I am using the wrong corner (see my pic)?

Any chance you are willing to attach your solution so I could verify please?

[davebYYPCU · Accepted solution]

Looks like you started over, so in that case, let's use the origin in the right place, and make everything so much easier to understand.  Walk along this timeline, you will notice that the mitre cut is done with split body because Extrude does not want to play nice.

Added your old file that I was editing, same thing done differently.

Might help....

[ptr727]

Thank you, I made two mistakes; wrong offset in extrusion 3, and I did not draw the extrude far enough out for the cut.

For the cases where extrude to plain fails the cut technique is good to know.

Thank you.