Rectangular post protrudes into interior of shelled loft object - how to remove protrusion?

frank_paynter

I have a shelled loft from a small 3x4mm rectangle to a 30mm circle, and this works now thanks to help from this forum.  Now I need to create a mounting post for a microphone and tie this into the loft object.  I created a new part from a sketch, and extruded it up and into the loft, but if mates properly on the outside it unfortunately protrudes into the interior of the loft object.  I tried using the boolean operator with the two parts (mic mounting post and loft), but none of the options ('union', 'subtract' and 'intersect') did what I want.  How do I solve this so it properly mates on the outside but the interior protrusion is removed?

Here's the project:  HearingAidTester_V1 | Part Studio 1 (onshape.com)

TIA,

Frank

GWS50

You could use the Split tool which lets you choose which side to keep, and then boolean together the remaining parts.
Boolean will work as well.....subtract the horn from the base but tick the Keep Tools box....then delete the part inside the horn and Boolean the other two parts together.
The Split option is better as it uses less steps.

glen_dewsbury

Another option is to Boolean add then delete faces.

https://cad.onshape.com/documents/b2851ecaf48f9db8aa103cb1/w/4c0a80f34ab399e74455f058/e/9febf0c08b9688f01b87b1a4

john_lopez363

@frank_paynter
Very easy.... just use the "Up to Face" operator with the Extrude feature.

frank_paynter

Nice!  Thanks for describing a very simple and elegant way to do this - I knew it had to be something simple!  I'm giving only a 9.95/10, though as you forgot to mention it doesn't work unless you also change the feature order so 'shell' comes immediately after 'Mic_to_SpkrMate_Loft'

Frank