TIG- found the problem with the Bool'd groups -BT can create a group inside a group when bool-ing more than two groups, which I should have spotted in Outliner.
When manifold highlighted RED and said 'NO' I simply exploded the extra group and answered my earlier ?, it was much faster on the bool'd group and I assume would be the similar on a manually repaired group.
Note for users: The manual option also gives more control over the mesh shape at the torus/box intersection.
Basically TIG you've done a fantastic job on this, thank you
I'm convinced you, Chuck, and I won't be the only end-user's for this, it has soo many uses.
for now I'll keep putting up images that help or hinder, and get back to some bent text testing....
do you think it's ready for a wider audience yet, I'm planing on trying to do a tutorial when your happy?
ADD: it's what I thought re: tri/quads, just thought I'd ask