when I rotated yours, I only moved around a few segments to avoid showing a tiny rotate…
e.g. 16.01˚ is more visual than 0.01˚, but in that case, does the same thing…
looking at your latest…
after removing the two faces, I zoom into the bottom one where you have ‘aligned geometry’ correctly…
when I then zoom in on the top one, you can see the tiny edges that misalignment causes…
they pull the shape out of round and if too small, will fail to create faces at all, leaving holes…
BTW: re-pasting the whole post just bogs down the thread…
you can use @Silverback to get someones attention or just highlight the text and quote that fragment…
john