Having trouble generating Shadow Outline from Mass Perimeter Curve

I’m having a bit of trouble generating shadow outline for the shadow study i’m currently conducting, currently the general idea is to :

  1. Project the perimeter edge of the mass
  2. Surface patch the edge
  3. Union them together to generate a singular surface that i can extract the perimeter edge from

However, I kept failing during union process, as they keep throwing INCONS_REL error, been struggling with it for a few days now, What am i doing wrong here ? I think i’m missing something here…

Any input and idea is appreciated.

Additional Note : Added RVT, DYN and additional images in google drive as i’m limited to one attachment as a new user.
https://drive.google.com/drive/folders/1jZFl41OtrfmyjMQbsu5FOJchVxTBBIC0?usp=drive_link

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