Hi Robert,

Ah! I get it now. Yes, the extra 3.142mm wont even allow the lid to get to the mating indentation. In all honesty, I religiously followed the autodesk tutorial but unfortunately it stops short of creating the half round pins in the lid. So, I had to take a guess and ended up creating the exact mating part to the base.

What would be the recommended radius for the half round pins in the lid? Or should I remove the half round pins from the two long sides. In the end, I need the enclosure to be reasonably fitting - just enough that my lid does not come off with minimal touch/motion.

Thanks so much for all your help. I am really grateful.