Starting working life as an Apprentice to the Refrigeration and Air-conditioning Trade I became intrigued by the tiny size of this duct. Because my Designs are created entirely using S3D it seemed reasonable to verify my suggestion(s).
Working with the Bottom portion of the duct revealed slight discrepancies in the profile of the mating face, so my attention was shifted to the Top portion of the Duct.
In the attached shapr. File Sketch 01 was created on the Top mating face and after completion the Top was moved 20mm in the [upward] Z direction and hidden so as not to impede the following actions.
To avoid the result becoming two separate Bodies both areas either side of Sketch 01 ‘dividing’ line were pulled downward by the same distance, then each area was pulled upward by the differing distances, deliberately exaggerated so that the heights could be adjusted to match the original.
The Top was unhidden and the resultant single Body [New Top] was Moved upward so that it nested inside the original Top.
The differing heights were adjusted to match the original and the Sloping faces were also manipulated [highlight the appropriate Edge of the Body and Move it into position] to match the Sloping Faces. Of course it would be better moving the Edges by precise measurements.
Highlight either the Top or New Top and Move them apart.
Lastly it seemed reasonable to see if the desired end result was possible? I.e., creating Union between the two Bodies.
The optimum MO would have been to keep the Bottom, Top and New stacked neatly by only Moving along the Z axis. Move Object(s) by distances that you record or can remember, it makes for simplicity when returning them to original positions.
I chose in this instance to displace the Top sideways before creating Sketch 01 and the New Top, it will simplify the task by not making unnecessary displacement sideways. Simply Hide anything that obstructs your work area.
However moving the New Top into its position on the Bottom, then performing the Union routine, worked first time.
I have used this opportunity to increase my knowledge regarding the capabilities of S3D. Doing is a great way of learning?
Duct T.shapr (4.7 MB)