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[AndyH]

I find with one object in particular thatsome vertices seem to join but others do not. If I align vertices to grid then they will join up when optimised.

So I think tried setting align to grid on everything and then duplicated the object but the same happened. I had to align vertices to grid again before they would join.

I will try again tonight to be sure, but do you want e to send you an AC file to look at? (please let me know where to send it).

I also found if I zoomed in- I mean REALLY zoomed in, to the vertices that eventually the vertices started 'jumping' around. I assumed this was due to the scale of such small values? When zoomed in this far, the ones that don't join jump about where as the ones that do, do not jump around. I also found at this zoom level pressing the middle mouse button to move the view did not work properly (it gets stuck on X/Y axis) which again I assumed is down to the tiny numbers loosing precision.