Re: How to obtain clean output from Boolean operations?
I don't think "clean" Booleans exist anywhere, with any program. They're always creating a mess, in my experience, especially if the shape you hope to arrive at is anything near complex (as a gear or bushing obviously is).
Best I've come to expect is that I can, relatively easily, identify groups of vertices I can weld together to produce the clean result.
With what you've got there, might I suggest trying to "trace" vertices to create a poly from a straight-on view of the result, and extrude that poly to get the finished product?
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