The problem is that SU was designed for quick prototyping on an architectural scale, not for producing extremely detailed models on a very small scale. I tried running the profile around the base but the corners simply refuse to work. This is because the result is way below SU’s level of tolerance. If you do exactly the same thing but with the model scaled up 100x then there’s no problem.
If you are going to work on stuff this small, then you are simply going to have to use cms instead of mms at the very least…as a matter of course…then scale down when done.
- Make sure the profile is aligned with the “top” edge, then move it somewhere down the side of the casing. Then ( selecting it by the end point that will eventually make contact with the side wall) move it inside the casing until that point is constrained by the face itself.
You already have a path…the outline of the base. It’s just that it’s an absolute ■■■■■ to select with all those separate segments around the curves. The quickest way of selecting it is to double-click the base so that both it and its outline are selected, then while holding down Shift, deselect the face itself…leaving just the outline. You’ll also need to deselect the edge of that hole you’ve drilled in it.
When you are left with just the outline selected, then orbit inside the casing so that you can see the profile you buried in there…then click it with the Follow Me tool. This should do what you want. (it did for me…when scaled up). But you’ll then have to delete both the original sharp edge all around…as well as the unrequired 2 flat faces of the extrusion. You’ll destroy the bottom face when doing this, but it can be easily re-established when you’ve finished all the cleaning up.
The Round Corners plugin I mentioned earlier would have required little to no tidying up. Alternately, running that profile on top of the existing surface (by anticipating that and making the sides consequently shallower to allow for the addition) would have required much less tidying up too. Using Follow me actually inside an existing surface like this really isn’t a very efficient method.