I'm not going to have a rough time because I can afford to spend 4 hours to figure out what is wrong. But new users? Maybe they won't.

Having a user modify defaults is not a good solution. A user should not need to know underlying behaviour/quirkiness to have a model be precise. IMBack showed code that works with correct radius, for other cases. Why not fix all locations to use correct radius? To an end user, it doesn't matter what...

Hmm. Is the default set for gui /rendering speed/memory savings? It seems like the more accurate, actual radius should always be used for cases when it would make a difference regardless of what the default is set to. Otherwise, going with a strategy of "Just switch a default, setting" the...

Just an FYI, With My file: I tried "mark to recompute" and then F5. It didn't fix the bug; holes are still too small. Also, as noted before, closing / reloading the file didn't fix the bug. I'm running V.18 (no other fixes, just the download that is available to everyone). With the "t...

When I saved the file and reloaded, the helix holes were still the wrong size. Wouldn't reloading do "a full recompute"? I also tried pressing f5 (does that do "a full recompute").

chrisb, Is this the additional "helix problem" you are having? If I start a new helix and select the circle "edges" (ie not the deep hole / faces), then Add them to the Helix, I see them in the list, but no path is generated. As a workaround, I need to first add a "deep hole...

heh heh, the bound box seems to mimic what I thought : the poligonal lines that make up the holes are smaller when the hole is rotated 90. Earlier I tried to workaround this by increasing the number of lines per circle (via all the "edit->preferences" settings), but I could find no attribu...

Sorry for the mix up of the file.
Is there a workaround that I could use to make the hole the correct size (other than creating 2 different models for different rotations)?
Is this bug being worked on already?

Thanks!

Attached.

I created a flat sheet with some 4.5mm holes, and create a clone of it and rotate the clone 90. Then I select the holes in each object and apply "helix" tool path. When I click on each of the helix paths, the diameter is different as shown in the base geometry. I measured and they are actu...