Hello deedub, Here's the "gotcha": the 45 degree angle is actually wider than the original cross section. The 45 Degree cut means that there is more wood to cut through because of the angle. How much wider? I don't care. I let the spline modeler do the thinking for me. 1. create a cross section, also select the last point on the pre-existing extrusion path and choose 'create cross section' from the pull down menu 2. select "pipeline" from the extrusion method pull down menu, 3. draw the path you want the cross section to follow. Sometimes the corners 'balloon' and get wider than they should. 1. under the extrusion envelope method, choose 'symmetrical in plan", grab the points on the corners and drag them back into alignment. Hope this helps. Mark