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Answers
I have now found that when I select from the menu it works perfectly without any other selections or deletions etc., but when I select from the model it fails. You can see why by looking at the the differences. ie. the good one just has the faces selected.
What puzzle me is that I have watched many of the training videos and found no reference to this. In fact they all seem to select on the model
https://cad.onshape.com/documents/077113744199d2407a4def6f/w/63cbc60e0505d463cccb6ad2/e/7368b9a2ee8715e9176684a5