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I'm almost positive this is an easy fix, but rather than spending additional hours on it, I've decided to reach out! I tried to use the Boolean modifier, but it didn't do anything. Am I using the wrong modifier? What's your best solution?

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after trying intersect (knife)

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  • $\begingroup$ Hello and welcome! It's quite easy. Just join the 2 objects by selecting both and pressing ctrl+j. Then tab into Edit Mode and select an intersecting face/s either the ones on the left or the ones on the right (but not both sides) and press Ctrl+F > intersect (knife). Notice how they merge. then press a then m >Merge By Distance. See example blender.stackexchange.com/a/280275/142292 $\endgroup$
    – Harry McKenzie ♦
    Commented Dec 5, 2022 at 14:45
  • $\begingroup$ Thanks for your speedy response! It doesn't seem to work for me. Perhaps there's something structurally wrong with my mesh? When I try the intersect (knife) bit, nothing merges. Only extra vertices are added. (see second img above) $\endgroup$
    – stfrdr
    Commented Dec 5, 2022 at 15:06
  • $\begingroup$ it shud work with any intersecting face. try a simple example first with 2 intersecting planes. select only 1 plane. $\endgroup$
    – Harry McKenzie ♦
    Commented Dec 5, 2022 at 15:15
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    $\begingroup$ @HarryMcKenzie that sounds like an answer! post it so we can upvote it ;) $\endgroup$
    – Luciano
    Commented Dec 6, 2022 at 9:52

3 Answers 3

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This isn't really a job for a Boolean, if you can avoid it...it's modelling.

One way would be to start with a couple of quads covering the region of interest:

enter image description here

  • I inset, by the thickness of the sill, and repeat, by the thickness of the inner rail.
  • X delete the inner face.

enter image description here

  • AltE extrude all faces along normals, by the depth of the inner rail. For all extrusions, ensure 'Even Thickness' is checked.
  • Alt Select the sill face-loop, and extrude to the depth of the sill.

For this result:

enter image description here

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I've managed to find my own way through this!

Here's what worked for me:

  1. Create a cube, and duplicate it.

  2. Merge them together so that the main cube we want is left with a frame-like shape and use the Boolean modifier. the L is the frame-like shape we want

  3. Apply the Boolean modifier, delete the extra cube.

  4. Scale/Tweak the dimensions to get desired size, then move from there with the insets and extrusions, etc.

Here are the final results!

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You can also join the 2 objects by selecting both and pressing Ctrl+J. Then tab into Edit Mode and select an intersecting face or faces, either the ones on the left or the ones on the right (but not both sides) and press Ctrl+F then select Intersect (Knife). Notice how they merge.

enter image description here

Then you can easily delete the excess geometry. Sometimes it generates other little funny geometry. Just dissolve any weird vertices that get generated.

enter image description here

And finally make sure to remove duplicate overlapping vertices by selecting all with A and pressing M > Merge By Distance.

enter image description here

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  • $\begingroup$ Although this taught me how to use knife intersect (thank you!), unfortunately, it's just creating too many weird vertices/edges on my mesh. I tried it with just the two basic planes and it worked like a dream! I guess my mesh is too wonky, but I'll definitely revert back to knife intersect more in the future! $\endgroup$
    – stfrdr
    Commented Dec 7, 2022 at 8:28
  • $\begingroup$ yeah I found it very useful as well! too bad it doesn't work on your mesh oh no.. XD can you share your blend file. I would like to understand what is going on with your mesh. blend-exchange.com $\endgroup$
    – Harry McKenzie ♦
    Commented Dec 7, 2022 at 8:48

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