[Al Skierkiewicz]

Indie,
I just saw your post. From what you describe, it sounds like you are working in 3D. When using the UNION command, some of the objects must intersect. In 3D it is difficult to see this sometimes. When drawing in 3D I use an oblique view (from the view toolbar) i.e. above right oblique. This give you a beter idea of where objects lie in the drawing. They may look like they overlap in your view but in reality are several drawings units apart. It is also helpful to have several UCS positions saved. When drawing or modifying objects that may require a rotation, I set a new UCS on the end point of one of the objects. Hope this helps.