Thank you TIG.
I didn't notice any highlights of the offending geometry.
Is there any other tool that can find the offending intersected geometry?
I'd like to know how it actually happened to being with, for future reference...
Anyway, thanks again for concisely explaining how to fix the issue.

p.s., I still get SketchUp Bug Splat if I put two of the same component in model. Does not happen if there are two different components, i.e., Main Rib Center & Outboard Center Rib.
I sent a Bug Splat report, Crash Report #73801. No response yet...

I created the components from the same source and made minor changes.
One has two ‘flats’, the other one ‘flat’.
I run Solid Inspector2 on both and they come up ‘No errors, shiny”
Running SolidSolver on Main Center Rib comes up ‘The Selected GROUP/INSTANCE is already a 'Solid' !’
Main Rib Center.skp

Running SolidSolver the Outboard Main Rib ‘This seemingly 'Solid' Selected GROUP/INSTANCE 'intersects' itself !’. SolidSolver then removes everything except the guide points...
Outboard Main Rib.skp

I’ve spent hours trying to find anything wrong…
Although the Entity info says it is a Solid Component in the model (and the exported .stl prints on the 3D printer) it is just bugging me!
Also, Sketchup will BugSplat! if I check and there are multiple components in the model.

What am I missing?

@dave r said:

...I used Curviloft ...

Thanks, I'll look at it and see if I can clean up my model.

@pilou said:

Maybe this can interest you!
TaffGosh the SketchUp Master of domes!

Verrrrry interesting... Thank you for the lead... lots of great information.

@dave r said:

... Maybe you need a coyote trap.

Trying to trap is problematic... don't want to draw them onto your land... a donkey will keep them away or kill them... then they stay away.

Your model of the strut is awesome... hope to be able to do modeling like you some day.
Especially like the way you were able to get the 'flat' really flat.

@dave r said:

Would this be close to what you're trying to achieve?...

eh.. pretty darn close... I just need to adjust the angle of the flat to the 'hub' angles for the dome struts, i.e., V1, V2, V3, etc...

That pic is much cleaner then what I have so far:

Trying to document the dome I've built... planned use to cover round bale hay and provide pasture shelters for goats and donkey's... yup got two (mother and daughter) to keep coyotes away... coyotes killed one of my goats and the neighbors cow

Anyway, here is the dome I built so far... need to make the skin.

@gilles said:

Fine, scaling up to X100 and processing a hole works fine and gives a solid.

I tried with VisuHole and it still did not work... could you give more detail? i.e., 'processing a hole'...

SolidSolver still gave 'nested groups' and would not fix...

I created circle, selected all, Scaled factor 100, opened VisuHole, selected stencil, applied at guide...

Edit: I did it over again and this time it worked... SolidSolver still found 'nested group' but fixed it

Thanks so much for your input...

@gilles said:

It may be tiny surface issue so scale up the model to X100 or X1000 before perform such operations, and post your model in SU 2015 version please.

I'll give it a whirl... here is 2015 version:
Make Hole in Flat (2015).skp

@moot said:

... I'm trying to get a hole through the flat... struggling... Can make the hole, but lose the 'solid'...

Well, I'm stumped... tried VisuHole. It made the hole all the way through the model but SolidSolver says there is 'nested group', tries to fix it - but can't...

Here's a pic with the guides for (3/16 radius) hole I want...

Make Hole in Flat.skp

@pilou said:

You must move points/segments of the inner together !
And make many more sections on each parts!
Your cylinder can't bend without more sections

Thanks... works great using FredoScale!

Now, just one more thing... I'm trying to get a hole through the flat... struggling, but I'm going to try to figure it out... Can make the hole, but lose the 'solid'... going to spend some time on it before I ask for help

Thank you sdmitch. I've got part of what I want now...
Now I'm trying to bend the flat section...

The Flat is a solid... problem is, when I get the 30 degree bend I can't make it solid... something I'm missing/doing wrong? I figure it has something to do with the curved surface intersecting the tube angle... but I can't seem to get rid of the extra edges/faces that are causing the model to keep from becoming a 'solid'

Strut.skp