As for the intersection you are likely right, they likely are intersecting a bit, I figured it looked reasonable though. But now that you point it out with your demonstartion tjohn (thx for the diagram btw) I supppose they likely are intersecting quite a bit more than I might like. As for the condoition of the blades I created them by making hieght maps from an actual scan of the blade from my reference knife. Maybe the bump is a bit too deep though?