Shell a Solid Bullbar Shape into Sheet metal issues

[benV7THH]

I'm trying to shell and use the bend and corner seam features to allow sheet metal flat patterns in 3-5 components. 

I can seem to get it to work successfully, I run into issues where the rip function in corner seam leave poor quality sections. and bends don't work. I have uploaded the file for people to download and see. I'm using 2022version 

[blandb]

Please see the attached 2022 part. I derived the part you sent into a new part as a surface and developed the sheet metal from that. I just used the gap size, I obviously dont know you rules, and was not going to take the time to digest it, but this will get you a concept on one way to do this. Hope that helps.

[blandb]

The above gives you an idea of how you could of made the part from scratch utilizing the same concepts (without deriving) by flanging at an angle to a certain width, using corner seams to close gaps, etc. If you need, I can do another part to show what I mean.

[benV7THH]

thank you, i can see the differences in the model tree. That's very helpful.