The issue is, every way I've built this, something fails to fuse. Strangely, sometimes it will fuse at first, and then many boolean operations later, it will break. So, is there a way to build one of these robustly? Maybe a loft? Any ideas are appreciated, and I'm using FreeCAD 0.18.
Things I've tried so far, that I can remember:
- Making the gusset a sketch, then extruding it, then filleting the edges. This had two problems. First, the fillet couldn't be the same radius as half the width of the extrusion, or it would fail. I made it 99.9% of that, and that worked at first, but later boolean operations caused issues.
- Using two other tori (not full 360's, but 90 degrees each), and then using an extruded sketch to fill in the last bit left over. This is what you can see in the image above. Although the three tori would fuse, it would not work with the final fusion of the extruded sketch.
- Using no torus, creating the whole thing from a sketch, and then filleting the necessary edges. This is very close to ideal, but you can't set the fillet radius to half the extrusion depth as that causes it to fail. If there's no better solution, I'll probably just use this with a radius 99.9% of half the extrusion depth.
