RobynsVeil,

Thank you very much.  I often put the models I make through a final STL error check, just to be sure they are "water tight";  with no open edges, overlapping edges, double faces, or isolated verts.  I guess it's a good habit; just something I've learned to do in our 3D design class.  We've done some modeling for 3D print there, so I tend to model things with that possibility in mind. :)

zandar,

Boolean operations would certainly be an easier approach here, but I try to keep as FAR away from booleans as possible when modeling.  Not that they aren't ever an option, but in most cases, booleans tend to result in bad topology, and destroy your UV's.  I'm sure some applications do boolean operations very well, and I know some software is based around modeling objects with booleans, but 3dsmax isn't one of them.

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