Looks like the mesh is double-sided. Editable Poly works under certain topology rules that prevent welding two polys back-to-back. Detach the backfaces to another element, and it should work.
yeah with nitrous enabled in shade mode it is really hard to see which is flipped and not. In dx mode you can see clearly. Thats a nice idea Eric.]Is there a script to flip all the normals in the same direction even if there are faces flipped in the wrong direction and some in the wanted direction? Edit: Nevermind found one
I remember when stuff like that always happened to me when modeling in Max and it would set me back forever. The other thing that still gets me is when the verts just disappear into La-La Land and you have to fiddle with the display settings, and reset the program 4 times over.
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[ame="http://www.youtube.com/watch?v=4s5oWmmV3JA"]This video[/ame] explains why the weld sometimes not work. I found it 2 minutes after I post this thread.