Booleans are very powerful and get a much undeserved bad reputation. I use them all the time. I come from a nurbs / hard surface background and in surfacing applications like Rhino, and professional design applications like Studio tools booleans are a staple part of creating shapes.
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The first video is about 15 minutes and covers the creation of the top section and the second video is only 5 minutes and shows how to create the bottom section for a perfectly fitted completed part.
I hope you find this helpful.
I am not sure how much bandwidth I have remaining on screencast.com so if I run out and you cannot run the video I will put another copy of both on YouTube.com later today.
Here is what we make:
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Here is the link to part 1 - the top section
https://www.screencast.com/t/YWVjODU5ZDk
Here is the link to part 2 - the bottom section
https://www.screencast.com/t/NzIxODEyY2
I don't put a lot of time into editing these and the narration is just done in a single take, so forgive me if I stutter or have occasional points of brain lock.
Please feel free to drop a comment to let me know if you find this stuff useful.
Cheers!
Can't find any other free sites that let me post a video longer then 10 minutes and too lazy to split the first part up so if I run out of bandwidth on screencast.com, it refreshes on the 3rd of the month.
Let me know if there is a free video stream hosting site that allow more then 10 minutes.
Thanks.