Trouble using shell feature on solid

[Anonymous]

I am having trouble shelling the feature at .105 inch.  I was able to before adding the last extrusion feature but would like to keep a uniform thickness throughout part for manufacturing purposes.  Any recommendations?

[blair]

Your first base sketch "Extrusion1" isn't fully constrained and can be dragged all over and into different shapes. The same can be said for the next feature/sketch "Extrusion27" as well.

Items 121-127 can be done with a simple loft. You are doing way to much work, I suspect some of the small extrusions from the middle of the Model Tree down are the source of your issue with the Shell.

This would be easier to fix by starting from scratch.

[WHolzwarth]

Here's a remedy (2016 file).

I removed one member of Fillet119. This was an external fillet of 0,0625 in and would result in a negative internal fillet of  -0.0425 in. Sometimes Inventor recognizes this problem and substitutes it with a sharp edge; in other times it doesn't proceed further.

You can create these last fillets after shelling manually

Walter